Method and apparatus for converting a manual transfer switch into an automatic transfer switch

A system for converting an installed manual transfer switch connected to one or more power supplies into an automatic transfer switch, comprising:

• an actuator attaching to the installed manual transfer switch and including a first actuator assembly that seats over a first lever on a first circuit breaker in the manual transfer switch and a second actuator assembly that seats over a second lever on a second circuit breaker in the manual transfer switch;
• an operator that moves the actuator into different positions that change how the manual transfer switch connects the power supplies to a load, the operator moving the first actuator assembly and the second actuator assembly mutually exclusive of each other into either an on position or an off position;
• and
• a controller that controls when the operator moves into the different positions according to sensed power on the power supplies.

A system for converting an installed manual transfer switch connected to one or more power supplies into an automatic transfer switch, comprising:

• an actuator attaching to the installed manual transfer switch;
• an operator that moves the actuator into different positions that change how the manual transfer switch connects the power supplies to a load, the operator including a cam coupled to a motor that controls movements of the actuator by rotating the cam in either a clockwise or counterclockwise direction;
• and
• a controller that controls when the operator moves into the different positions according to sensed power on the power supplies.

A system for converting an installed manual transfer switch connected to one or more power supplies into an automatic transfer switch, comprising:

• an actuator attaching to the installed manual transfer switch;
• an operator that moves the actuator into different positions that change how the manual transfer switch connects the power supplies to a load;
• a controller that controls when the operator moves into the different positions according to sensed power on the power supplies;
• and
• cam followers preventing the actuator from moving from the different positions instigated by the operator.

A system for converting an installed manual transfer switch into an automatic transfer switch, comprising:

• a conversion assembly that mechanically mounts onto the installed manual transfer switch and mechanically moves the manual transfer switch into different switching configurations that couple different power supplies to a load, the conversion assembly including a single motor operator that controls all movements of the conversion assembly:
• a controller electrically coupled to the conversion assembly that automatically moves the conversion assembly into different positions according to a power status of the power supplies;
• and
• a conversion door exchangeable with a door on an electrical panel box that holds the manual transfer switch wherein the conversion door holds the controller and includes an electrical cable that electrically couples the controller to the conversion assembly.

A system for converting an installed manual transfer switch into an automatic transfer switch, comprising:

• a conversion assembly that mechanically mounts onto the installed manual transfer switch and mechanically moves the manual transfer switch into different switching configurations that couple different power supplies to a load, the conversion assembly including a single motor operator that controls all movements of the conversion assembly;
• a controller electrically coupled to the conversion assembly that automatically moves the conversion assembly into different positions according to a power status of the power supplies;
• and
• a conversion door exchangeable with a door on an electrical panel box that holds the manual transfer switch wherein the conversion door extends the depth of the panel box by about three inches.

A method for converting an installed manual transfer switch having first and second switches into an automatic transfer switch, comprising:

• providing a conversion assembly;
• mechanically mounting the conversion assembly directly onto the installed manual transfer switch;
• electrically coupling a controller to the conversion assembly that automatically controls movements of the conversion assembly;
• monitoring power supplies connected to the manual transfer switch with the controller;
• automatically moving the conversion assembly into different positions to change the switching arrangements of the manual transfer switch according to the monitored power supplies;
• and
• controlling an amount of time the first one of the switches and the second one of the switches both remain turned off by moving the conversion assembly into an intermediate position.

A method for converting an installed manual transfer switch into an automatic transfer switch, comprising:

• providing a conversion assembly;
• mechanically mounting the conversion assembly directly onto the installed manual transfer switch;
• electrically coupling a controller to the conversion assembly that automatically controls movements of the conversion assembly;
• monitoring power supplies connected to the manual transfer switch with the controller;
• automatically moving the conversion assembly into different positions to change the switching arrangements of the manual transfer switch according to the monitored power supplies;
• rotating a cam in the conversion assembly in a first direction to turn off a first switch in the manual transfer switch and turn on a second switch in the manual transfer switch;
• and
• rotating the cam in a second direction to turn off the second switch and turn on the first switch.

An automatic transfer switch, comprising:

• a first switch controlling connection of a first power supply to a load;
• a second switch controlling connection of a second power supply to the load;
• an actuator attaching to the first and second switch and moving the first and second switch into different on and off positions;
• an operator moving the actuator into different positions including a first position where the first switch is in an on condition and the second switch is an off condition, a second position where the first switch is in an off condition and the second switch is in an on condition and a third position where the first and second switch are both in an off condition;
• and
• a controller moving the actuator into the different positions according to power levels on the first and second power supplies.

An automatic transfer switch, comprising:

• a first switch controlling connection of a first power supply to a load;
• a second switch controlling connection of a second power supply to the load;
• an actuator attaching to the first and second switch and moving the first and second switch into different on and off positions wherein the actuator includes a first actuator assembly that seats over a lever on the first switch and a second actuator assembly that seats over a lever on the second switch;
• an operator moving the actuator into different positions wherein the operator includes a motor sitting in between the first and second switches and a cam coupled to the motor that moves the actuator by rotating in either a clockwise or counterclockwise direction;
• and
• a controller moving the actuator into the different positions according to power levels on the first and second power supplies.