ABB ATS022 Fail-Safe Auto Transfer Switch for Industrial Control

Overview

ABB ATS022 Fail-Safe Auto Transfer Switch for Industrial Control Reliability

The ABB ATS022 Automatic Transfer Switch is engineered for mission-critical industrial environments where uninterrupted power continuity is non-negotiable. Designed to deliver fail-safe switching performance, the ATS022 protects continuous production lines, critical interlock circuits, and heavy-duty control cabinets from the consequences of mains power failure, voltage sag, or supply interruption. Whether deployed in petrochemical processing, power generation, mining extraction, water treatment, metallurgical smelting, or port logistics, the ATS022 provides the rapid, reliable source changeover that keeps operations running safely and without unplanned downtime.

In high-electromagnetic-interference environments — including variable frequency drive cabinets, large motor control centers, and arc furnace switchgear rooms — the ATS022 maintains stable switching logic without signal drift or false triggering. Its robust EMC-rated enclosure and surge-tolerant input circuitry ensure that transient voltage spikes, inductive load switching, and ground noise do not compromise transfer accuracy. For dusty, humid, high-temperature, or high-vibration field conditions, the ATS022’s sealed construction and wide operating temperature range sustain reliable performance across seasonal extremes and harsh process environments.

The ATS022 integrates seamlessly into ABB’s broader power protection and control architecture. In a typical critical power cabinet, it operates alongside the ABB SACE Emax2 air circuit breaker for upstream fault isolation, the ABB UPS DPA series for bridging power during transfer intervals, and the ABB CM-EFS.2 voltage monitoring relay that continuously supervises mains quality and triggers the ATS022 changeover command when supply parameters fall outside safe thresholds. For facilities running ABB Ability™ SCADA or System 800xA DCS, the ATS022’s digital status outputs feed directly into the control network, enabling supervisory visibility of transfer events, source availability, and fault logs without additional signal conditioning hardware.

In safety instrumented systems and emergency shutdown architectures, the ATS022 supports the power continuity requirements of SIL-rated interlock loops. When paired with the ABB Relion 615 series protection relay and the ABB REF615 feeder protection IED, the ATS022 ensures that safety-critical field devices — including solenoid valves, emergency stop circuits, and fire and gas detection panels — remain energized during mains disturbances. This layered protection strategy reduces the risk of spurious trips, process upsets, and personnel hazards caused by momentary power loss in safety-critical zones.

For facilities managing aging infrastructure or executing phased modernization programs, the ATS022 serves as a reliable bridge component. It is backward-compatible with legacy ABB SACE S-series breaker panels and can be integrated into new IEC 60947-6-1 compliant switchgear assemblies without requiring full cabinet redesign. Spare units are maintained in multi-region stock for emergency replacement, with pre-shipment functional testing completed on every unit prior to dispatch. A support terms confirmed by quotation cover all ATS022 units, providing procurement teams and maintenance engineers with the supply assurance needed for long-term asset management planning.

Fail-Safe Reliability Table

Control Cabinet Protection Strategy

A robust control cabinet protection strategy built around the ATS022 begins with upstream fault isolation. The ABB SACE Emax2 air circuit breaker provides selective coordination and arc flash protection at the main incomer, ensuring that downstream faults do not propagate to the transfer switch or critical load circuits. The ABB CM-EFS.2 voltage monitoring relay continuously evaluates mains quality — monitoring for undervoltage, overvoltage, phase loss, and phase sequence faults — and issues the transfer command to the ATS022 when supply conditions deteriorate beyond safe operating limits.

During the transfer interval, the ABB UPS DPA series provides seamless bridging power to critical loads, eliminating the brief interruption that would otherwise affect sensitive PLC processors, HMI panels, and safety relay modules. Once the ATS022 completes the changeover to the standby source, the ABB Relion 615 series protection relay monitors the alternate supply for stability before confirming safe operation. For facilities with distributed I/O architectures, the ABB AC500 PLC series can be configured to supervise ATS022 status signals and log transfer events to the plant historian, supporting maintenance audits and regulatory compliance reporting.

In high-vibration or high-dust environments such as mining headframes, cement plant control rooms, and offshore platform switchgear cabinets, the ATS022’s sealed construction and vibration-rated mounting hardware prevent contact wear and insulation degradation that would otherwise shorten service life. Periodic replacement of the ATS022 as a planned maintenance spare — supported by in-stock availability and support terms confirmed by quotation coverage — is a cost-effective strategy for eliminating unplanned downtime risk in critical power distribution panels.

Critical Industrial Safety Applications

Petrochemical and Refinery Plants: In continuous process facilities where power interruption triggers emergency shutdown sequences, the ATS022 maintains power continuity to critical interlock panels, flame and gas detection systems, and emergency depressurization valve actuators. Rapid transfer times prevent spurious ESD activations that would require lengthy restart procedures and production loss.

Power Generation and Substation Control: The ATS022 protects auxiliary power supplies for protection relay panels, bay control units, and communication gateways in HV/MV substations. Reliable source changeover ensures that protection functions remain active during grid disturbances, preventing unprotected operation of power transformers and transmission lines.

Mining and Mineral Processing: In underground and surface mining operations, the ATS022 supports power continuity for ventilation control systems, conveyor interlock circuits, and winder safety systems. Its vibration tolerance and wide temperature range make it suitable for harsh surface and underground electrical rooms.

Water and Wastewater Treatment: Municipal and industrial water treatment facilities rely on the ATS022 to maintain power to pump control panels, dosing system PLCs, and SCADA communication infrastructure during utility supply interruptions, preventing treatment process upsets and regulatory compliance violations.

Metallurgical and Smelting Operations: High-current arc furnace facilities and rolling mill control rooms use the ATS022 to protect sensitive control electronics from the severe voltage disturbances generated by large inductive loads, ensuring that process control systems remain operational throughout the production cycle.

Port and Marine Logistics: Shore power distribution panels and vessel electrical systems benefit from the ATS022’s fast transfer capability, maintaining power to cargo handling control systems, navigation electronics, and safety lighting during source switching operations.

Safety and Quality FAQ

Q: Does the ABB ATS022 come with a support terms?
A: Yes. Every ATS022 unit supplied by KNMKS is covered by a support terms confirmed by quotation from the date of shipment. Support terms coverage includes manufacturing defects, component failure under normal operating conditions, and functional performance against published specifications.

Q: Is pre-shipment testing performed on each ATS022 unit?
A: Yes. All ATS022 units undergo functional pre-shipment testing prior to dispatch. Testing verifies transfer switching operation, control input response, output contact continuity, and insulation integrity. Test records are available upon request for quality assurance documentation.

Q: Is the ATS022 compatible with existing ABB switchgear and protection relay systems?
A: The ATS022 is designed for integration within ABB’s power protection ecosystem and is compatible with ABB SACE series circuit breakers, Relion series protection relays, CM-series monitoring relays, and ABB AC500 PLC control systems. It also supports legacy ABB SACE S-series panel installations, making it suitable for both greenfield and brownfield projects.

Q: What is the long-term supply availability for the ATS022?
A: KNMKS maintains multi-region stock of the ATS022 to support emergency replacement, planned maintenance programs, and capital project procurement. Global dispatch is available with short lead times. For high-volume or scheduled procurement requirements, contact our sales team to discuss dedicated stock reservation and supply agreements.

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ABB
ABB

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ATS022

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Sensors

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