Neutral Conductor Loss in Residential Photovoltaic Installations: Overvoltage Analysis and Design of a Contactor-Based Automatic Transfer Switch

The widespread adoption of photovoltaic systems in residential electrical installations has increased the importance of Automatic Transfer Switches (ATSs) for ensuring power continuity during grid outages. However, many low-cost ATS solutions available on the market prioritize economic efficiency over operational safety, leading to significant risks under fault conditions. This paper investigates a real overvoltage incident in a residential three-phase installation equipped with a photovoltaic inverter and an ATS, which resulted in the failure of multiple electronic loads. The study reconstructs the event and demonstrates that the loss of the neutral conductor during backup operation caused severe phase voltage imbalance, generating overvoltage conditions across lightly loaded phases. A simplified electrical model is used to explain current paths and voltage redistribution under asymmetric loads, highlighting the critical role of correct neutral switching in ATS design. Two commercially available ATS architectures, one based on a changeover-contact mechanism and one employing four-pole miniature circuit breakers, are experimentally evaluated. The evaluation reveals major design deficiencies, including the absence of protective elements for control circuits, reliance on mechanical end-position limiters, and the use of switching devices not intended for frequent source transfer. These shortcomings introduce risks such as uncontrolled actuator operation, overheating, mechanical damage, and potential fire hazards. To overcome these limitations, a new ATS architecture was developed using a phase-monitoring relay, interlocked ABB contactors, and dedicated fuse protection for all control circuits. Detailed laboratory measurements were conducted to characterize contactor switching times and internal relay command delays. By optimizing the command sequence, the proposed ATS achieves predictable, fault-tolerant operation with competitive transfer times, representing a meaningful safety improvement over the evaluated commercial alternatives. The proposed solution is scoped to three-phase residential installations equipped with a hybrid photovoltaic inverter providing a dedicated backup output, operating within TN-S or TN-C-S earthing systems with a maximum grid connection capacity of 21 kW.