Cummins onan wotpcc power generation transfer switch 40 1000 amperes service repair manual

Service Manual

Transfer Switch 40−1000 Amperes

WOTPCB (Spec A) WOTPCC (Spec A) WOTPCD (Spec A)

English − Original Instructions

3-2010

A030H989 (Issue 1)

Table of Contents SECTION 1.

2.

TITLE

PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IX

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Switch Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Utility-to-Genset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Utility-to-Utility Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator-to-Generator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prime Power (Plant to Plant) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual Stand-By Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Levels 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-5 1-7 1-7 1-7

COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bargraph Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Factor Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Membrane Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Security Key Switch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Control Circuit Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-Wire Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Start-Stop Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programmed Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programmable Generator Exerciser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Imbalance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1 2-1 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-3 2-3 2-3 2-5 2-5 2-6 2-6 2-7 2-7 2-7 2-7 2-8 2-8 2-8 2-8 2-9

i

Table of Contents SECTION

3.

(Continued)

TITLE

PAGE

Phase Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loss of Single Phase Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator-to-Generator Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Utility-to-Utility Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Retransfer Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Relays Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relay Module Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Current and Power Sensor Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Shed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PowerCommand Network Interface Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Shed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Sequencing Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and Replacing Electronic Control Components . . . . . . . . . . . . . . . . . .

2-9 2-9 2-9 2-9 2-10 2-10 2-11 2-11 2-11 2-13 2-13 2-14 2-16 2-16 2-17 2-17 2-17 2-17 2-17 2-17

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

Functional Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programmed Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer/Re-Transfer Inhibits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Engine Start (TDESa, and TDESb) . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Engine Cooldown (TDECa, and TDECb) . . . . . . . . . . . . . . . . . . . .

Time Delay Normal to Emergency (TDNE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Emergency to Normal (TDEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Programmed Transition (TDPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Elevator Time Delay (TDEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Under-Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Over-Voltage Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Imbalance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1 3-1 3-1 3-1 3-1 3-1 3-2 3-2 3-2 3-2 3-3 3-3 3-3 3-3 3-3 3-4 3-5 3-5 3-6 3-7 3-8

ii

Table of Contents SECTION

4.

(Continued)

TITLE

PAGE

Phase Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loss of Single Phase Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sync Check Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Tests, Exercises, and Exercise Exceptions . . . . . . . . . . . . . . . . . . . . . .

Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Start Test Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Start Test With Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Programmable Generator Set Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setting Exercise(s) − Starting with Software Version 1.5.190 . . . . . . . . . . .

Setting Exercise Exception(s) − Starting with Software Version 1.5.190 .

Setting Exercise(s) − Starting with Software Version 1.13.244 . . . . . . . . . .

Setting Exercise Exception(s) − Starting with Software Version 1.13.244 Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With-Load Standby System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8 3-8 3-9 3-10 3-10 3-10 3-10 3-10 3-11 3-11 3-12 3-13 3-14 3-15 3-16 3-16 3-16 3-16 3-17 3-17

DIGITAL DISPLAY MENU SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Password and Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 1 and Source 2 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Statistics Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Events Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Menu Navigation and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Setup Parameters − Starting with Software Version 1.12 . . . . . . . . . .

Sensor 1 & Sensor 2 Submenus − Starting with Software Version 1.12 . . . . . . .

Sync Check Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . .

Test Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exerciser Submenus − Starting with Software Version 1.5.190 . . . . . . . . . . . . . .

Exercise Exceptions Submenus − Starting with Software Version 1.5.190 . . . . .

Exercise Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . .

4-1 4-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-13 4-14 4-16 4-17 4-19 4-21

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5.

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TITLE

PAGE

Exercise Exceptions Submenus − Starting with Software Version 1.12 . . . . . . .

Exercise Submenus − Starting with Software Version 1.13.244 . . . . . . . . . . . . . .

Exercise Exceptions Submenus − Starting with Software Version 1.13.244 . . .

Mode Submenu − Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . . .

Clock Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequencer Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Submenus − Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . .

System Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Active TD Submenus − Starting with Software Version 1.12 . . . . . . . . . . . . . . . . .

4-23 4-25 4-27 4-29 4-30 4-31 4-32 4-34 4-35

EVENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

Event Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Locked Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fail to Retransfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fail to Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S1 Failed to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S1 Failed to Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S2 Failed to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S2 Failed to Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-Fault Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CT Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Start A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Start B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exercise in Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exercise Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fail to Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator A Common Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator B Common Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Sequencer Outputs (1-8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Network Wink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Neutral Current Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not in Auto: ATS Motor Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not in Auto: Common Output (Network Only) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not in Auto: Load Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not in Auto: Retransfer Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not in Auto: Transfer Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Phase Rotation Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preferred Source 1 (or 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Tool Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 1 Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1 5-1 5-1 5-1 5-1 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-4 5-4 5-4 5-4 5-4 5-4 5-4

iv

Table of Contents SECTION

6.

(Continued)

TITLE

PAGE

Source 1 Connected or Bypassed Source 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 1 Loss of Phase Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 1 Over-Voltage Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 1 Over/Under Frequency Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 1 Under-Voltage Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 1 Voltage Imbalance Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 2 Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 2 Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 2 Loss of Phase Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 2 Over-Voltage Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 2 Over/Under Frequency Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 2 Under-Voltage Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Source 2 Voltage Imbalance Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sync Check Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sync Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test In Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Start A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Engine Cool-Down (TDEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Programmed Transition (TDPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Source 1 (N) to Source 2 (E) (TDNE) . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Source 2 (E) to Source 1 (N) (TDEN) . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Start A (TDES-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delay Start B (TDES-B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Pending (TDEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-6 5-6

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

InPower Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About Network Applications and Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control LED Indicators and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exerciser Enable/Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer from Source 1 to Source 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer from Source 2 to Source 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Using Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Flash-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Event Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Checksum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1 6-1 6-1 6-2 6-2 6-2 6-2 6-3 6-3 6-4 6-5 6-5 6-5 6-5 6-8 6-8

v

Table of Contents SECTION

7.

(Continued)

TITLE

PAGE

Low Controller Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATS Fail to Close: Re-Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATS Fail to Close: Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Network Communications Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting With Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-8 6-8 6-8 6-8 6-8 6-9 6-9

TRANSFER SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Removing and Replacing Electronic Control Components . . . . . . . . . . . . . . . . . . 7-1 Membrane Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Power Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Power Module 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Power Module 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Digital Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Setup with a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Setup Without a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 After the Setup is Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 Switch Assembly Removal/Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . 7-8 Disconnect AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Reconnecting AC Power (When Finished) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Linear Actuator Removal and Replacement (40 to 125 Amperes, Three Pole Transfer Switches Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Block and Cross-Bar Assembly Removal and Replacement (40 to 125 Amperes, Three Pole Transfer Switches Only) . . . . . . . . . . . . . . . . 7-11 Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . 7-11 Replacing the Block and Cross-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 Auxiliary Switch Removal and Replacement (40 to 125 Amperes, Three Pole Transfer Switches Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Linear Actuator Removal and Replacement (150 to 260 Amperes Transfer Switches and 40 to 125 Amperes, Four Pole Transfer Switches) . . . . . . . . . 7-17 Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 Block and Cross-Bar Assembly Removal and Replacement (150 to 260 Amperes Transfer Switches and 40 to 125 Amperes, Four Pole Transfer Switches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . 7-20

vi

8.

Replacing Block and Cross-Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Switch Removal and Replacement (150 to 260 Amperes Transfer Switches and 40 to 125 Amperes, Four Pole Transfer Switches) . . . . . . . . .

Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Linear Actuator Removal and Replacement (300 to 600 Amperes) . . . . . . . . . . .

Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Block and Cross-Bar Assembly Removal and Replacement (300 to 600 Amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Block and Cross-bar Assembly (Normal or Emergency) . . . . .

Replacing the Block and Cross-bar Assembly (Normal or Emergency) . . . . .

Auxiliary Switch Removal and Replacement (300 to 600 Amperes) . . . . . . . . . .

Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Linear Actuator Removal and Replacement (800 and 1000 Amperes) . . . . . . . .

Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Block and Cross-Bar Assembly Removal and Replacement (800 and 1000 Amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing the Block and Cross-bar Assembly (Normal or Emergency) . . . . .

Replacing the Block and Cross-bar Assembly (Normal or Emergency) . . . . .

Auxiliary Switch Removal and Replacement (800 and 1000 Amperes) . . . . . . . .

Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mis-Wired Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-38 7-38 7-42 7-43 7-43 7-44 7-45

SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

vii

7-23 7-24 7-24 7-24 7-26 7-26 7-26 7-29 7-29 7-32 7-33 7-33 7-34 7-35 7-35 7-35

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viii

Safety Precautions This manual includes the following symbols to indicate potentially dangerous conditions. Read the manual carefully and know when these conditions exist. Then take the necessary steps to protect personnel and the equipment.

1. Move the operation selector switch on the generator set to Stop.

DANGER This symbol warns of immediate hazards that will result in severe personal injury or death.

3. Remove AC power to the automatic transfer switch. If the instructions require otherwise, use extreme caution due to the danger of shock hazard.

2. Disconnect the starting batteries of the generator set or sets (remove the ground [−] lead first).

WARNING This symbol refers to a hazard or unsafe practice that can result in severe personal injury or death.

UTILITY-TO-UTILITY APPLICATIONS

This symbol refers to a hazard or unsafe practice that can result in personal injury or product or property damage.

If the cabinet must be opened for any reason, remove AC power to the automatic transfer switch. If the instructions require otherwise, use extreme caution due to the danger of shock hazard.

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

GENERAL PRECAUTIONS

CAUTION

High voltage in transfer switch components presents serious shock hazards that can result in severe personal injury or death. Read and follow these suggestions.

Keep the transfer switch cabinet closed and locked.

Make sure only authorized personnel have the cabinet and operational keys.

Due to the serious shock hazard from high voltages within the cabinet, all service and adjustments to the transfer switch must be performed only by an electrician or authorized service representative.

Place rubber insulative mats on dry wood platforms over metal or concrete floors when working on any electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surfaces to be damp when handling any electrical equipment.

Jewelry is a good conductor of electricity and should be removed when working on the electrical equipment.

Wear safety glasses whenever servicing the transfer switch and and do not smoke near the batteries.

Do not work on this equipment when mentally or physically fatigued, or after consuming alcohol or any drug that makes the operation of equipment unsafe.

UTILITY-TO-GENSET OR GENSET-TO-GENSET APPLICATIONS If the cabinet must be opened for any reason:

WARNING

INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH, SEVERE PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/ OR MECHANICAL SERVICE.

ix

WOTPC-1

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x

1. Introduction ABOUT THIS MANUAL

NORMAL

This manual contains service procedures for an WOTPC automatic transfer switch (ATS). This is an open transition (OT) transfer switch with PowerCommandÂŽ Control (PC). With an open transition switch there is never a time when both sources are supplying power to the load.

OVERCURRENT PROTECTIVE DEVICE

Refer to the schematic and wiring diagram package that was shipped with the ATS for specific information about its configuration.

Use normal and necessary safety precautions before starting any service procedure. Identify all hazards by referring to the Safety Precautions and observe all warnings and cautions within the manual.

Whenever you are troubleshooting, remember that the generator set, ATS, and utility power source are all interdependent.

LOAD

TRANSFER SWITCH APPLICATIONS Transfer switches are an essential part of a building’s standby or emergency power system. Power Source 1 (Normal), commonly the utility line, is backed up by Power Source 2 (Emergency), often a generator set. The transfer switch automatically switches the electrical load from one source to the other.

OVERCURRENT PROTECTIVE DEVICE

EMERGENCY

The load is connected to the common of the ATS (Figure 1-1). Under normal conditions, the load is supplied with power from Source 1 (as illustrated).

If Source 1 is interrupted, the load is transferred to Source 2. When Source 1 returns, the load is retransferred to Source 1. The transfer and retransfer of the load are the two most basic functions of a ATS.

FIGURE 1-1. LOAD TRANSFER SWITCH (TYPICAL FUNCTION)

Cummins is a registered trademark of Cummins Engine Company.

Onan is a registered trademark of Onan Corporation.

PowerCommand is a registered trademark of Onan Corporation.

1-1

TRANSFER SWITCH FUNCTION Automatic transfer switches, capable of automatic operation without operator intervention, perform the basic function of transferring the load to the available source. The controller monitors each source for allowable voltage and frequency range.

Preferred Source

Source 1/Source 2

Level 2 Controllers Only

The WOTPC ATS supports utility-to-generator, utility-to-utility, and generator-to-generator applications.

FIGURE 1-2. PREFERRED SOURCE SUBMENU

UTILITY-TO-GENSET OPERATION

GENERATOR-TO-GENERATOR OPERATION

In utility-to-genset applications, the transfer switch performs the following functions:

In genset-to-genset applications, there are two possible configurations, as shown in Figure 1-3.

1. Senses the interruption of the Source 1 power.

2. Sends a start signal to the generator set (Source 2).

3. Transfers the load to the Source 2.

4. Senses the return of Source 1.

5. Retransfers the load to Source 1.

6. Sends a stop signal to the generator set.

UTILITY-TO-UTILITY OPERATION In utility-to-utility applications, the transfer switch performs the following functions: 1.

2.

3.

4.

• Prime Power − Two gensets provide all of the power (utility power is not available) • Dual Standby − Two gensets are used to back up utility power In Prime Power genset-to-genset applications, the ATS performs the same as with utility-to-genset applications.

In Dual Standby genset-to-genset applications, the master and the slave ATSs perform the following functions.

1. The slave ATS begins connected to the preferred source (either genset A or B, but neither genset is operating yet) and monitors for the Stand-by Start signal from the master ATS (see Figure 1-3).

2. When the signal is received, the slave ATS starts the preferred genset.

3. If the preferred source voltage is acceptable, the slave ATS remains there and turns off the non-preferred genset. Otherwise, the slave ATS will transfer to the non-preferred source.

4. When the utility source returns on the master ATS, then it will transfer back to the utility and disables the Stand-by Start signal.

5. When the Stand-by Signal is disabled, the slave ATS turns off the operating genset (either genset A or B).

Senses the interruption of the Source 1 power.

Transfers the load to the Source 2.

Senses the return of Source 1.

Retransfers the load to Source 1.

If one genset fails to operate within the specified range of voltage and frequency, the transfer switch automatically starts and connects the other genset.

Level 2 controllers can control a two-utility configuration for prime power. One utility is designated the preferred source. The control automatically transfers the load between the two utilities and detects alarm conditions.

The operator can select either source as the preferred source (see Figure 1-2). The Preferred Source menu is included in the Test submenus (see Figure 4-13). The PC service tool can also be used to designate either source as the preferred source.

Note: The Test/Exercise function and Load Shed feature are not available in this configuration.

Note: The exercise routine is not available in this configuration.

In prime power applications, utility power is not available. The system includes one transfer switch

Prime Power (Plant to Plant) Operation

1-2

and two gensets (see Figure 1-3). One genset is always running and supplying power to the load while the other genset is the backup genset. An external power supply is not needed in this application.

At any time, the PC service tool or the Test submenu (see Figure 1-2) can be used to designate either genset (Source 1 or Source 2) as the preferred genset. The Preferred Source menu is included in the Test submenus (see Figure 4-13).

Preferred Source Selection − Under normal operation, one genset is designated as the preferred source and supplies power to the load. The second genset is the backup power source. If the preferred genset fails, the backup genset starts and the transfer switch transfers the load to the backup genset.

If the user manually changes the preferred source setting so that the backup genset becomes the preferred genset, the transfer switch transfers the load to the new preferred genset when it becomes available. The unit that is carrying the load is always considered the preferred source. The control doesn’t automatically select which source is considered preferred.

GENSET B

GENSET B

OVERCURRENT PROTECTIVE DEVICE

UTILITY OVERCURRENT PROTECTIVE DEVICE

MASTER ATS STAND-BY START LOAD

SLAVE ATS

LOAD

OVERCURRENT PROTECTIVE DEVICE OVERCURRENT PROTECTIVE DEVICE GENSET A

OVERCURRENT PROTECTIVE DEVICE GENSET A

GEN-TO-GEN CONFIGURATION IN PRIME POWER MODE

GEN-TO-GEN CONFIGURATION IN DUAL STANDBY MODE

FIGURE 1-3. GENERATOR-TO-GENERATOR CONFIGURATION IN PRIME POWER AND DUAL STANDBY MODES

1-3

2. Place the transfer switch in the Source 1 position.

Automatic Changeover − The transfer switch can be set up to change the preferred source automatically by enabling the changeover timer. The Time Delay sub-menus under Setup (see Figure 4-12, depending upon your software version) or the PC Service tool can be used to enable the changeover timer and specify a changeover delay time period.

3. Place the Off−Manual−Auto selector switch on the Source 1 genset control in the Auto position. The genset will start and supply power to the load (the load will be energized and TDECa may be timing).

The automatic changeover timer automatically changes the preferred source and transfers the load to the new preferred genset after a TDEN time delay. After the transfer is complete, the control initiates a cool-down period (TDEC) on the old preferred genset before shutting it down. The old preferred genset is now the new backup genset. The changeover timer is now timing for the next changeover and the cycle continues as long as the changeover timer is enabled.

4. Use the PC Service tool or the Test sub-menu to set this genset as the preferred source.

5. Wait for TDECa to finish timing.

6. Place the Off−Manual−Auto selector switch on the backup genset (Source 2) control in the Auto position.

7. Place the motor disconnect switch in the Auto position.

8. If desired, use the Time Delay sub-menus under Setup or use the PC Service tool to enable the changeover timer and specify a changeover delay time period.

Changeover Enable

Enabled/Disabled

CHANGEOVER ENABLE/DISABLE

Testing the System by Turning Off the Preferred Source:

Changeover Delay

24 Hours

1. With the preferred source genset running and supplying power to the load, place the genset control Off−Manual−Auto selector switch in the Off position. The backup genset should start and run.

CHANGEOVER TIME DELAY

Level 2 Controllers Only

After the voltage and frequency are at acceptable levels, the transfer switch should transfer the load to the backup genset.

FIGURE 1-4. CHANGEOVER SUBMENUS

Prime Power Wiring − A permanent start jumper is installed in the transfer switch and is shipped from the factory in the prime power mode. Verify that the jumper (TB3-57 to TB3-59) is installed (see interconnect drawing 626−2108, sheet 1 in Chapter 8).

2. Place the genset control Off−Manual−Auto selector switch on the preferred genset back in the Auto position. The preferred genset should start and run.

System Startup − To set up a system for prime power operation:

After the voltage and frequency levels are at acceptable levels, the transfer switch should transfer the load back to the preferred genset.

1. Place the motor disconnect switch in the Off position, and both generator selector switches into the OFF position.

After the transfer is complete, the control initiates a cool-down period (TDEC) on the backup genset and it should stop.

1-4

Testing the System by Changing the Designated Preferred Source: 1. With the preferred source genset running and supplying power to the load, use the PC Service tool or the Test sub-menu to change the preferred source. The new preferred source should start and run.

After the voltage and frequency are at acceptable levels, the transfer switch should transfer the load to the new preferred source.

After the transfer is complete, the control initiates a cool-down period (TDEC) on the old preferred source and it should stop.

2. Use the PC Service tool or the Test sub-menu to change the preferred source back to the original genset. The original genset should start and run.

After the voltage and frequency levels are at acceptable levels, the transfer switch should transfer the load back to the original genset.

After the transfer is complete, the control initiates a cool-down period (TDEC) on the backup genset and it should stop.

Dual Stand-By Operation In dual stand-by applications, utility power is available. The system includes two transfer switches and two gensets. Utility power supplies power to the load and both gensets are backup gensets.

Under normal operation, the utility is supplying power to the load through the lead transfer switch.

The lead transfer switch is a utility-to-genset switch. The two gensets are connected to the genset-to-genset transfer switch. The load side of this switch is connected to the genset side of the lead transfer switch.

Upon loss of utility power to the lead transfer switch, a signal is sent to the genset-to-genset transfer switch to start the preferred genset. When the lead transfer switch senses generator voltage, it transfers the load to that genset. If the preferred genset fails to start, a signal is sent to the backup genset to start. The PC Service tool or the Test submenu on the genset-to-genset transfer switch can be used to set the preferred source.

If the Stand-By Start is inactive, upon initial power– up (or reset), or during software initialization, the

transfer switch control will not start either genset.

When a Stand-By Start command is received from a Master ATS (or other device), the preferred genset immediately starts. If the preferred genset does not start, a time delay engine start (TDES) is initiated and the control starts the backup genset. The load is connected to the genset when it becomes available.

If the preferred genset becomes available while the backup genset is active, a time delay retransfer (TDEN) period is initiated and the load is retransferred back to the preferred genset. A time delay cool-down (TDEC) period is initiated before turning off the backup genset. When the Stand-By Start becomes deactivated, a TDEC period is initiated and the active generator is turned off.

Preferred Source Selection − Under normal operation, one genset is designated as the preferred source and the second genset is designated as the backup power source. If the both the utility power and the preferred genset fails, the backup genset starts and the genset-to-genset transfer switch transfers the load to the backup genset.

At any time, the PC Service tool or the Test sub– menu on the genset-to-genset transfer switch can be used to designate either genset (Source 1 or Source 2) as the preferred genset. If the preferred genset is changed and the backup genset becomes the preferred genset, the transfer switch transfers the load to the new preferred genset if it is needed and when it becomes available.

Alternating Preferred Source − In an attempt to keep the running time equally distributed between both gensets, the control can be set to alternate between the gensets when utility power fails. The selected preferred genset starts with the first power outage. The second power outage starts the backup genset, which now becomes the preferred genset. Upon subsequent outages, the preferred genset alternates.

Only utility outages and tests or exercises initiated at the lead transfer switch result in the gensets being alternated. The designated preferred genset will not change if it fails and the backup genset takes over the load. This alternating preferred source can only be enabled with the PC Service tool. When enabled, a genset can be designated as the preferred source for a maximum of two weeks. Time adjustments can be made in one-hour increments.

1-5

Control Voltage − A dual stand-by configuration requires an external 12−24 VDC power supply to keep the genset-to-genset control active. An optional Battery Kit is available, or the genset starting batteries can be used. See drawing 630−2024 for connection details.

Dual Stand-By Wiring − For dual stand-by applications, the jumper (TB3-57 to TB3-59) must be removed (see interconnect drawing 630−2024 in Chapter 8).

10. Set the time delay engine stop (TDECa) to zero on the lead transfer switch.

11. If desired, use the PC Service tool to enable the alternating preferred source.

12. Place the motor disconnect switch in the Auto position on both transfer switches.

Testing the System by Removing Utility Power and Turning Off the Preferred Genset:

System Startup − To set up a system for dual stand-by operation:

1. With the utility supplying power to the load and neither genset running, turn off the utility circuit breaker feeding the load transfer switch. The preferred genset should start and run.

1. Place the motor disconnect switch on both transfer switches in the Off position.

After the voltage and frequency are at acceptable levels, the lead transfer switch should transfer the load to the preferred genset.

2. Connect both transfer switches to the Source 1 side.

3. Make sure the Off−Manual−Auto selector switch on both gensets is in the Off position.

2. Place the Off−Manual−Auto selector of the preferred genset (running) control in the Off position.

4. Make sure the genset-to-genset transfer switch is being powered by an external DC supply.

The preferred genset should stop and the backup genset should start and run.

5. Press the Lamp Test/Reset button on the genset-to-genset transfer switch. If all of the front panel lights come on, the control is running properly.

After the voltage and frequency are at acceptable levels, the genset-to-genset transfer switch should transfer the load to the backup genset.

6. Use the PC Service tool or the Test sub-menu on the genset-to-genset transfer switch to set the Source 1 genset as the preferred source.

3. Place the Off−Manual−Auto selector switch on the preferred genset back to the Auto position.

The preferred genset should start and run.

7. Energize utility power to the lead transfer switch. The load is energized and a time delay (TDECa) begins.

After the voltage and frequency are at acceptable levels, the genset-to-genset transfer switch should transfer the load to the preferred genset. The backup genset should stop after the time delay engine cool-down (TDECa) is completed.

8. Wait for TDECa to finish timing.

9. Set the time delay engine start (TDESa) to zero on the lead transfer switch.

1-6

CONTROL LEVELS 1 AND 2

Note: Refer to the next section for a list of feature/ option codes.

Two controls are available. The type of power source switched and the desired features determine the control levels available. See the Description section for details. The table lists the applications that are available with each control.

TABLE 1-1. AVAILABLE CONTROL LEVELS Power Sources

Level 1

Level 2

Genset-to-Utility

X

X

Genset-to-Genset

X

Utility-to-Utility

X

The model number is made up of code segments that designate various features or options: W _ PC _ _ _ _ _ | | | | | | | | 1 2 3 4 5 6 7 8 1. Schnider Wingoal (Tian Jing) electric equipment co, LTD 2. Switch type OT − Open transition BT − Bypass 3. PC − PC (Type)

The control board level can be viewed, using the digital display (see Figure 1-5). This menu is included in the About submenus (see Figure 4-23, depending upon software version).

4. Amperage (A) : 40, 70, 125, 150, 225, 260, 300, 400, 600, 800, 1000, 1200, 1600, 2000, 3000, 4000 5. Poles − 3, 4

ATS Board Level

6. Transfer type: S − Sync check D − Delay

2

FIGURE 1-5. CONTROL LEVEL SUBMENU

7. Controller type: 1 − Level 1 control 2 − Level 2 control

MODEL IDENTIFICATION Identify your model by referring to the Model and Specification number as shown on the nameplate.

Electrical characteristics and application information are shown on the lower portion of the nameplate. The nameplate is located on the cabinet door.

If it’s necessary to contact a dealer or distributor regarding the transfer switch, always give the complete Model, Specification, and Serial number as listed on the nameplate. This information is necessary to properly identify your unit among the many types manufactured.

8. Feature

HOW TO OBTAIN SERVICE When the transfer switch requires servicing, contact Schneider Electric at +8622 8371 2900 Ext − 875. Factory−trained Parts and Service representatives are ready to handle all your service needs.

When contacting Schneider Electric, always supply the complete Model, Specification and Serial Number as shown on the nameplate.

1-7

FEATURE DESCRIPTION

FEATURE OPTION

FEATURE DESCRIPTION

Poles: 3 Poles 4 Poles

Phase: A028 A029

1 Phase, 2-W or 3-W 3 Phase, 3-W or 4-W

Application: Utility to Genset Utility to Utility Genset to Genset

Digital Bar Graph Meters 24 VDC Coil Emergency Position Normal Position Genset Start 12 VDC Coil Emergency Position Normal Position Genset Start

A046 A064 A044 A045

Voltage: 120 VAC 190 VAC 208 VAC 220 VAC 240 VAC 380 VAC 416 VAC 440 VAC 480 VAC 600 VAC

Terminal Block − 30 Position Load Shed − From Emergency Power Connect − Bus Stubs

M003 M007 N009

Cabinet: Type 30 Type 34 Type 65 Open Construction Type 61 Type 65 − Stainless Steel

C023 C024

Control Options: Front Panel Security Key Digital Display LONWORKS Network Com. Module Load Monitoring Relay Module

L101 L102 L103 L104 L201 L202 L203 L204

Miscellaneous: R020 R038 R021 R022 R023 R024 R025 R035 R026 R027

Controls: Level 1 Switch Control Level 2 Switch Control

D009

Auxiliary Relays:

Frequency: 60 Hertz 50 Hertz

A041 A042

Meters: A035 A036 A037

Agency Approvals: IP Listing NFPA 20

FEATURE OPTION

M017 M018 M020 M022 M023

1-8

B001 B002 B003 B004 B010 B025

2. Component Description CABINET The standard cabinet meets the requirements of the IEC for a IP Type 30 cabinet. This type is designated as a general-purpose, indoor cabinet. Cabinets are available in IP types 30, 34, 65 and 61.

CONTROL PANEL The control panel (See Figure 2-1) includes one or more of the following three panels.

• Bargraph Meter Panel

An examples of a cabinet, showing interior components is shown in Figure 2-5.

• Switch Panel

The front of the cabinet door includes the control panel, door handle, and the optional key switch.

• Digital Display

BAR GRAPH METER PANEL (LEVEL 1 NA, LEVEL 2 OPTIONAL)

SWITCH PANEL (STANDARD)

OPTIONAL KEY SWITCH

DIGITAL DISPLAY (LEVEL 1 OPTIONAL LEVEL 2 STANDARD)

FIGURE 2-1. CONTROL PANEL ON CABINET DOOR (INCLUDES OPTIONS)

2-1

BARGRAPH METER PANEL

SWITCH PANEL

The analog Bargraph Meter Panel is not available with Level 1 control and is optional with Level 2 control. Green, red and amber LEDs provide at-aglance indication of system acceptability. Features include a three phase AC ammeter, a power meter, a power factor meter, a frequency meter, and a three phase AC voltmeter.

The switch panel (Figure 2-3) is a standard feature on all WOTPC transfer switches. It contains six indicator lamps and three membrane buttons.

AC Ammeter The ammeter displays percent of full load currents in amperes (1−125%).

Power Meter The power meter displays the real power in percent of full load in kilowatts (0−125%).

Power Factor Meter The power factor meter displays the real power delivered to the load (1.0 − 0.6 lagging) and (1.0 − 0.9 leading).

FIGURE 2-3. SWITCH PANEL

Indicator Lamps Source 1 Available and Source 2 Available These indicators are lit when the corresponding sources have acceptable output voltage and/or frequency. These indicators can be lit simultaneously.

Frequency Meter

Source 1 Connected

This meter displays the output frequency (percent of nominal frequency), of the power source connected to the load (70−110%).

This indicator is lit when the ATS is in the Source 1 position and Source 1 is supplying power to the load.

AC Voltmeter The voltmeter displays percent of line to neutral voltages of the power source connected to the load (70−110%).

Source 2 Connected This indicator is lit when the ATS is in the Source 2 position and Source 2 is supplying power to the load.

Not in Auto For all configurations, the Not in Auto indicator lights when the ATS is not in Auto.

The transfer switch is not in auto when any of the following signals are active: Motor Disconnect Switch is set to Off Fail-to-Disconnect event is active Control is locked out Wiring harness is disconnected from J12 on the Power Module • Controller is set to Offline • The Operator Release key switch is in the Unlocked (Manual) position − This only applies to models that include the optional external manual operation handle.

• • • •

FIGURE 2-2. BARGRAPH METER PANEL

2-2

Test/Exercise Active The Test/Exercise Active indicator is lit when the ATS has a test or exercise in progress.

Membrane Buttons Test For utility-to-genset applications, the Test switch sends a start signal to the generator set designated Source 2 and blinks the Test/Exercise Active indicator. After the start and transfer time delays or source synchronization, Source 2 starts and assumes the load provided that the With Load option is selected. Press the Test switch again to end the test; the Test/Exercise Active indicator goes out and Source 1 resumes as the source of power.

For utility-to-utility applications, the Test switch starts the transfer time delay or source synchronization and the non-preferred Source assumes the load, provided that the With Load option is selected. Press the Test switch again to end the test; the Test/Exercise Active indicator goes out and the preferred Source resumes as the source of power.

events and resets active faults (refer to Events on page 3-16).

DIGITAL DISPLAY The Digital Display is standard on Level 2 controls and optional on Level 1 controls. It contains a 2-line by 20-character digital display module and 6 momentary contact membrane buttons. The display provides a method for monitoring load power condition, adjusting transfer switch parameters, monitoring PowerCommand Network status, or reviewing transfer switch events. It is password protected to limit access to unauthorized adjustments.

The module displays the software menus and the buttons are used to navigate through the menu system.

Each menu indicates the function of the four switches at the sides of the display module. Not all buttons are active for each menu. See Section 4: Digital Display Menu System, for details on the complete digital display menu structure.

For genset-to-genset applications, there is no test function.

Override The Override switch terminates most system time delays. The Program Transition (TDPT), Elevator signal (TDEL) and Engine Cool Down (TDEC) are not affected by this button. If you press this switch while the Transfer Inhibit input is active, the switch immediately transfers the load. If you press this switch while the Retransfer Inhibit input is active, the switch immediately retransfers the load. For more information on Transfer Inhibit, see page 2-10. For information on Retransfer Inhibit, see page 2-10.

FIGURE 2-4. DIGITAL DISPLAY

SECURITY KEY SWITCH OPTION

Reset/Lamp Test

The optional security key switch is located on the front panel between the handle and the Control Panel. When it is in the Panel Lock position, it disables the front panel input switches, Test and Override. It also prevents changes to the Digital Display from the setup menus; however, the current values are displayed. Changes can be made when the switch is in the Program position.

The Reset/Lamp Test button turns on all control panel indicators. This switch also acknowledges

The key switch can be disabled in PowerCommand using the PC service tool.

The Override function is not available unless the front panel switch is in the Program position.

2-3

BAR GRAPH ASSEMBLY NETWORK COMMUNICATIONS MODULE (NCM)

CONTROLLER BATTERIES

PC SERVICE TOOL CONNECTOR

TB1

AUTOMATIC TRANSFER SWITCH

DIGITAL MODULE P1 POWER (CONTROL) DISCONNECT

RELAY ASSEMBLY

MOTOR DISCONNECT SWITCH (S1)

DIGITAL DISPLAY

TB2

POWER MODULE

FIGURE 2-5. INTERIOR/COMPONENTS: 40-125 AMP SWITCH

2-4

TRANSFER SWITCH HANDLES

ELECTRONIC CONTROL SYSTEM

CURRENT PRODUCTION BATTERY J20

This section describes the standard and optional components of the electronic control system.

J26

J22

WARNING Improper calibration or adjustment of electronic control modules can cause death, severe personal injury, and equipment or property damage. Calibration and adjustment of these components must be performed by technically qualified personnel only.

Calibration and adjustment procedures are described in the Installation manual (which is shipped with the ATS).

J24

Accidental actuation of the linear motor could cause severe personal injury. Before making any adjustments, place the Motor Disconnect Switch (Figure 2-5) in the Off position. Return the switch to the Auto position after adjustments are completed.

J28 K10 J25

WARNING

J27

FIGURE 2-6. LEVEL 1 DIGITAL MODULE

J20

J29

J26 BATTERIES J26

AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal injury or death. When the cabinet door is open, use extreme caution to avoid touching electrical contacts with body, tools, jewelry, clothes, hair, etc.

WARNING

Electronic Control Circuit Modules The WOTPC transfer switch control incorporates a Digital and a Power Module. Two versions of each are available: one for Level 1 controls and one for Level 2 controls. The power modules are available in four different voltage ranges (240 VAC 1 phase 3 wire, 208−240 VAC 3 phase 4 wire, 380−480 VAC 3 phase 4 wire, and 600 VAC 3 phase 4 wire). The digital module has two 3-volt batteries to power the real-time clock when no source voltage is available. When replacing these batteries, change them one at a time.

Digital Module: The digital module (see Figures 2-6 and 2-7) contains the logic and timing circuits that control transfer switch operation. These modules also contain many of the customer interface circuits (including the genset start signal and network port), the RS-232 communications port for the service tool, and drivers for the control panel indicators, switches, and bar graph meter panel.

J24

J28

J25 J27

FIGURE 2-7. LEVEL 2 DIGITAL MODULE

Power Module: The power modules contain a power supply for the digital modules, voltage sensing transformers, and relays. These modules also contain the interface circuits for the transfer switch including the position sensing switches and relay drivers.12 VDC rectification and regulation circuits on this module are powered by both sources through transformers.

The Level 1 power module has three transformers allowing power from either source (1 or 2) for the switch components. The connections for two transformers on Source 1 are A-B and B-C. Source 2 transformer is connected at A-C.

2-5

Level 1 power modules contain four pilot relays defined: K12 K13 K14 K15

TO J24 ON THE DIGITAL MODULE J11

Neutral to Source 1 Source 2 to Neutral Neutral to Source 2 Source1 to Neutral

T8

J13

T5 TB12

TB14

K12 K14 T7

TO J24 ON THE DIGITAL MODULE J11

J12

K15

T4

K13

J12

K16

K14

K17

T3

TB11

TB13

K12

T6

K13 K15

T1

T2

T2

T1

FIGURE 2-9. POWER MODULE 2

T3

Motor Disconnect Switch TB11

FIGURE 2-8. POWER MODULE 1

The Level 2 power module contains eight transformers. Each source (1 and 2) use three transformers. Both sets are connected A:N, B:N and C:N except on 120 volt switches which are connected A:N only. The other transformers are used to power the 12 VDC supply on the module. One transformer is connected to Source 1 and the other source 2.

Level 2 power modules contain six pilot relays defined: K12 K13 K14 K15 K16 K17

Neutral to Source 1 Source 2 to Neutral Neutral to Source 2 Source1 to Neutral Closed Transition Enable Not Used

The Motor Disconnect toggle switch, on the control plate, enables and disables the linear actuator motor (see Figure 2-5). This switch is accessible only from inside the enclosure. The Not In Auto LED on the front panel indicates the state of this switch. It is lit when the switch is in the Off position. (Other ATS conditions also light this indicator: See the description of the Not in Auto indicator under Switch Panel on page 2-2). Place the switch in the Auto position to enable the linear actuator. Place the switch in the Off position to disable the linear actuator.

Two-Wire Starting The starting circuit is a basic supervisory function of the electronic control. Water-cooled generator sets use a two-wire start control.

Although the logic is more involved, the two-wire starting circuit can be thought of as a single pole, single throw switch. A closed switch starts the generator set. An open switch stops the generator.

NOTE: Three-wire starting is not available on WOTPC transfer switches.

2-6

Auxiliary Contacts Auxiliary contacts, used for external alarm or control circuitry, are available for the Source 1 (Normal) and Source 2 (Emergency) sides of the transfer switch. Connections for the auxiliary contacts can be made on terminal block TB1 (Figure 2-10). The contacts have ratings of 10 amperes at 250 VAC. Figure 2-10 shows the normally open and normally closed positions of the auxiliary contacts with the transfer switch in the neutral position. Moving the transfer switch to Normal or Emergency actuates the corresponding auxiliary contacts.

(TB2−3). For gensets requiring a dry contact closure for genset start do not use the jumper. Connect RMT (TB2−4) and TB2−2 to the genset start contacts.

NO

SOURCE 1 (NORMAL) AUXILIARY SWITCH

NC

1

GND

2

2

3

B+

4

RMT

5

REMOTE TEST

6

TRANSFER INHIBIT

7

LOAD SHED (OPTIONAL)

8

COMMON

COM TB2

FIGURE 2-11. TB2: START CONNECTIONS, REMOTE TEST, AND TRANSFER INHIBIT

NO

SOURCE 2 (EMERGENCY) AUXILIARY SWITCH

NC COM

TB1

FIGURE 2-10. TERMINAL BLOCK TB1

Remote Start-Stop Connections Use 0.75 mm2 to 4 mm2 stranded wire. Resistance must not exceed 0.5 ohms per line. For connection to the screw terminal strip the insulation back 10 mm.

Terminals 1 − 4 on TB2 are used for remote starting. The ATS control closes the RMT contact (TB2−4) to TB2−2 when a genset start is required.

Connect RMT (TB2−4) to the genset start signal.

For gensets requiring a grounded start signal connect the jumper between TB2−2 and ground (TB2−1). For gensets requiring a battery start signal connect the jumper between TB2−2 and B+

Programmed Transition Program Transition introduces a delay (TDPT) during transition of the switch. Programmed transition stops the switch in the neutral position for an adjustable interval of time. In this position, the load is not connected to either Source 1 or 2. This delay allows residual current from inductive loads to decay to an acceptable level before transfer is completed.

The parameters are adjustable. The length of time that the ATS is in the neutral position can be adjusted from 0 to 60 seconds in 1 second increments. The default value is 0 seconds. The proper adjustment is a function of the load. This feature is enabled by default. The values are set with PC service tool or the digital display.

Transfer Times The controller senses and records the time it takes for the ATS to break from one source and reconnect to the other source. (Transfer times are not recorded if Programmed Transition delay is in use).

2-7

Test With or Without Load The operator can test the ATS, generator, and power system automatically. The operator can transfer the load during the test or to only test the generator.

Both hardware means (switch input) and software means (PowerCommand network) input can activate an automatic test sequence.

Programmable Generator Exerciser

set. The load is transferred to Source 2 when Source 2 becomes available.

A jumper can be temporarily connected between TB2-5 and TB2-8 to test this feature.

Opening a set of contacts across the remote test transfer input causes the transfer switch to sense that utility power has been restored and transfers the load back to Source 1.

Programmable generator exercises and exercise exceptions are generally programmed to be recurring. They can be programmed from the PC service tool or the digital display when it is available.

1 GND 2 2 3 B+

Level 1 controllers include two programmable generator exercises and two programmable exercise exceptions. While all events can be set using the PC Service tool, only one exercise and one exercise exception can be set with the digital display.

4 RMT 5 REMOTE TEST 6 TRANSFER INHIBIT 7 LOAD SHED (OPTIONAL)

Level 2 controllers include eight programmable generator exercises and eight programmable exercise exceptions. While all events can be set using the PC Service tool, only two exercises and two exercise exceptions can be set with the digital display.

All controllers have a push-button switch on the digital module that enables and disables the exerciser clock. See the Digital Display Menu System section for details on setting the clock. The RealTime clock must be set before exercise programs are entered.

For utility-to-genset configurations, the exerciser clock initiates genset start and run cycles at specified intervals for specified durations. The exerciser is not used in utility-to-utility or genset-to-genset configurations (see Generator-to-Generator Control Mode).

Remote Test Switch The transfer switch may be wired with a remote test switch.

For utility-to-genset applications, closure of a set of contacts across the remote test transfer input (TB2-5 and TB2-8 − see Figure 2-12) causes the transfer switch to sense a (simulated) utility power failure and sends a start/run signal to the generator

8 COMMON

TB2

FIGURE 2-12. TB2 CONNECTIONS FOR REMOTE TEST TRANSFER

For utility-to-utility applications, closure of a set of contacts across the remote test transfer input (TB2-5 and TB2-8) causes the transfer switch to sense a (simulated) power failure of the primary source and transfers the load to the backup source.

Opening a set of contacts across the remote test transfer input causes the transfer switch to sense that the primary source has been restored and transfers the load back to the primary source.

This feature is not available with genset-togenset applications.

Real-Time Clock All controllers have a real-time clock that keeps track of the time and date. This clock is year 2000 compliant. The controller uses the real-time clock to time and date stamp all events.

Note: The clock is not set at the factory. To set the clock, use the digital display or PC Service tool.

2-8

Voltage Imbalance Sensor

Loss of Single Phase Sensor

Three phase Level 2 controllers include a voltage imbalance sensor for both Source 1 and Source 2.

This feature informs the operator when there is significant voltage imbalance between the phases of Source 1 or Source 2. This feature is used for equipment protection.

Three phase Level 2 controllers include a loss of single phase sensor. This feature initiates a transfer from a source that has lost a single phase and prevents a transfer to a source that has lost a single phase. This is generally caused by a single phase to line ground or open. The controller indicates a fault when the relative phase angle between any line-to-line phase angle drops to less than 90 . This feature is mainly used to protect three phase devices, such as motors.

A voltage imbalance is typically caused by severe single phase loading. The sensor indicates a failure when the maximum deviation from the average voltage is greater than a user-specified value between 2 and 10 % (drop-out) of the average voltage in 1% increments. The pickup value is fixed at 10% of the drop-out. The time delay for the imbalance sensor drop-out is adjustable (2−20 seconds).

The operator can enable this sensor. See the Digital Display Menu System section. This sensor is inactive for single phase systems and indicates no failures. To prevent nuisance faults, the setting can be increased up to 10 % of the nominal voltage.

Phase Rotation Sensor Three phase Level 2 controllers include a phase rotation sensor. This feature monitors the phase rotation of the source opposite from the connected source. When the alternate source is out of phase rotation with the connected source, transfer is inhibited. This generally occurs on new installations or after storm damage or generator rewiring. This feature protects against equipment damage by preventing transfer to a source that is out of phase.

This feature is required in fire pump applications.

CAUTION Level 1 controls do not support three-phase sensing on Source 2. Do not select the three-phase option for the Source 2 Sensing adjustment with Level 1 controls, even if the system is three phase. This setting will prevent Source 2 from becoming available.

Both voltage sources have to be applied in order to check phase rotation. Generally, a power source may become out of phase rotation in new installations, after a storm, or when there is generator rewiring.

This feature is enabled by default. To disable it, see the Digital Display Menu System section.

The operator can enable this sensor. See the Digital Display Menu System section. This sensor is inactive for single phase systems and indicates no failures.

Generator-to-Generator Control Mode Level 2 controllers can control a two-generator configuration for either dual standby or prime power. One generator is designated the preferred source. The control automatically transfers the load between the two generators and detects generator alarm conditions. This configuration requires the optional Battery Kit when used in dual standby mode.

The operator can select the preferred source (Source 1 or Source 2) in the genset-to-genset mode. The preferred source selection is made at the digital display (under Test).

A separate changeover timer automatically transfers loads between the two generators. The changeover timer is set from the digital display or the PC Service tool. The exerciser clock is not available in this configuration.

Utility-to-Utility Control Mode Level 2 controllers can control a two-utility configuration for prime power. One utility is designated the preferred source. The control automatically transfers the load between the two utilities and detects alarm conditions. The exerciser clock is not available in this configuration.

The operator can select either source as the preferred source. See the Digital Display Menu System section.

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Transfer Inhibit Input This feature is used to control load transfer to gensets. When activated, load transfer will not take place unless the Override button on the switch panel is pressed or the transfer inhibit input is disabled.

A transfer inhibit input is set up by connecting a remote contact between TB2-6 and TB2-8 (see Figure 2-13). Closing the contact enables the feature and opening the contact disables it. When enabled, the event is displayed on the front panel.

This feature can also be activated through a network or with the PC service tool. A jumper can be temporarily connected between TB2-6 and TB2-8 to test this feature.

1 GND 2 2 3 B+ 4 RMT 5 REMOTE TEST

Retransfer Inhibit Input This feature is used to prevent the ATS from automatically transferring the load back to Source 1 (or the preferred source in genset-to-genset applications). When activated, load retransfer will not take place unless the Override button on the switch panel is pressed, the retransfer inhibit input is disabled, or Source 2 (or the backup source in genset−to−genset applications) fails.

NOTE: If Source 2 (or the backup source in genset-to-genset applications) fails, the Retransfer Inhibit is ignored.

Retransfer Inhibits are set up by connecting a remote contact between TB3-53 and TB3-54 (see Figure 2-14). Closing the contact enables the feature and opening the contact disables it. When enabled, the event is displayed on the front panel. For TB3 location inside the transfer switch cabinet, see Figure 2-16.

6 TRANSFER INHIBIT 7 LOAD SHED (OPTIONAL)

TB3

8 COMMON

TB2

FIGURE 2-14. TB3 CONNECTIONS FOR RETRANSFER INHIBIT

FIGURE 2-13. TB2 CONNECTIONS FOR TRANSFER INHIBIT

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