Service Manual Transfer Switch (1200 Amp) OTECE (Spec A) English 3-2011 A035K570 (Issue 1) Original Instructions
TableofContents 1.SAFETYPRECAUTIONS..............................................................................................................1 1.1ElectricalShockandArcFlashCanCauseSeverePersonalInjuryorDeath.......................1 1.2GeneralPrecautions...............................................................................................................1 1.3Utility-To-UtilityApplications...................................................................................................2 1.4Utility-To-GeneratorSetorGeneratorSet-To-GeneratorSetApplications............................2 2.INTRODUCTION............................................................................................................................3 2.1ServiceManual.......................................................................................................................3 2.2ModelIdentification.................................................................................................................3 3.DESCRIPTION...............................................................................................................................5 3.1ModelOTECE.........................................................................................................................5 3.2FeatureDescriptionsandOptions..........................................................................................5 3.3Utility-to-GeneratorSetOperation..........................................................................................6 3.4Cabinet....................................................................................................................................6 3.5ECControlPanel....................................................................................................................7 3.6ElectronicControlSystem......................................................................................................9 3.7ControlOptions.....................................................................................................................13 3.82-Amp/10-AmpFloatBatteryChargerOption.......................................................................14 3.92-AmpBatteryCharger.........................................................................................................15 3.1015/12-AmpBatteryCharger................................................................................................17 3.11RemovingandReplacingElectronicControlComponents.................................................20 4.OPERATION................................................................................................................................21 4.1ManualOperationofTransferSwitches...............................................................................21 4.2ControlPanelConfiguration..................................................................................................21 4.3TimeDelays..........................................................................................................................29 4.4Sensors.................................................................................................................................32 4.5SystemTesting.....................................................................................................................34 4.6PushbuttonOperation...........................................................................................................36 4.7GeneratorSetExerciser.......................................................................................................37 4.8ExternalExerciseClockOption............................................................................................39 5.TRANSFERSWITCHSERVICE..................................................................................................67 5.1SwitchAssemblyRemoval/ReplacementProcedures..........................................................67 5.2DisconnectACPower...........................................................................................................67 A035K570(Issue1) i
TableofContents 3-2011 5.3ReconnectingACPower(WhenFinished)...........................................................................67 5.4LinearActuatorRemovalandReplacement.........................................................................68 5.5BlockandCross-BarAssemblyRemovalandReplacement................................................80 5.6AuxiliarySwitchRemovalandReplacement........................................................................96 6.TROUBLESHOOTING...............................................................................................................105 6.1AboutCustomerInputs.......................................................................................................105 6.2ControlPanelLEDIndicators.............................................................................................105 6.3SequenceofEvents............................................................................................................108 6.4TroubleshootingWithSymptoms........................................................................................112 6.515/12-AmpBatteryChargerTroubleshootingandFaults...................................................120 ii A035K570(Issue1)
1SafetyPrecautions
Thismanualincludesthefollowingsymbolstoindicatepotentiallydangerousconditions.Read themanualcarefullyandknowwhentheseconditionsexist.Then,takethenecessarystepsto protectpersonnelandtheequipment.
DANGER:Thissymbolwarnsofimmediatehazardsthatwillresultinsevere personalinjuryordeath.
WARNING:Thissymbolreferstoahazardorunsafepracticethatcanresultinsevere personalinjuryordeath.
CAUTION:Thissymbolreferstoahazardorunsafepracticethatcanresultinpersonalinjury orproductorpropertydamage.
1.1ElectricalShockandArcFlashCanCauseSevere PersonalInjuryorDeath
Highvoltageintransferswitchcomponentspresentsseriousshockhazardsthatcanresultin severepersonalinjuryordeath.Readandfollowthesesuggestions:
· TheOperator must alwayskeepthetransferswitchcabinetclosedandlocked.
· Makesureonlyauthorizedpersonnelhavethecabinetkeys.
· Allserviceandadjustmentstothetransferswitch must beperformedonlybyanelectrician orauthorizedservicerepresentative.
NOTE:Wheneverclosedtransitionisused,approvaltoparallelwiththelocalelectric utilitymustbeobtained.
1.2GeneralPrecautions
RefertoNFPA70EStandardforElectricalSafetyintheWorkplacetobesuretheproper personalprotectiveequipment(PPE)iswornaroundthisproduct.
Followtheseguidelineswhileworkingonoraroundelectricalequipment.
· Placerubberinsulatedmatsondrywoodplatformsovermetalorconcretefloorswhen workingonanyelectricalequipment.
· Donotweardampclothing(particularlywetshoes)orallowskinsurfacestobedampwhen handlinganyelectricalequipment.
· Removealljewelrywhenworkingonelectricalequipment.
· Wearsafetyglasseswheneverservicingthetransferswitch.
· Donotsmokenearthebatteries.
· Donotworkonthisequipmentwhenmentallyorphysicallyfatigued,orafterconsuming alcoholoranydrugthatmakestheoperationofequipmentunsafe.
WARNING:Incorrectserviceorreplacementofpartscanresultindeath,severepersonal injury,and/orequipmentdamage.Servicepersonnelmustbequalifiedto performelectricaland/ormechanicalservice.
A035K570(Issue1) 1
1.3Utility-To-UtilityApplications
Ifthecabinetmustbeopenedforanyreason:
· RemoveACpowertotheautomatictransferswitch.Iftheinstructionsrequireotherwise, useextremecautionduetothedangerofshockhazard.
1.4Utility-To-GeneratorSetorGeneratorSet-ToGeneratorSetApplications
Ifthecabinetmustbeopenedforanyreason:
1.MovetheoperationselectorswitchonthegeneratorsettoSTOP.
2.Disconnectthebatterycharger.
3.Disconnectthestartingbatteriesofthegeneratorsetorsets(removetheground[-]lead first).
4.RemoveACpowertotheautomatictransferswitch.Iftheinstructionsrequireotherwise, useextremecautionduetothedangerofshockhazard.
1.SafetyPrecautions 3-2011
2 A035K570(Issue1)
2Introduction
2.1ServiceManual
ThismanualcoversmodelsproducedundertheCummins® andCumminsPowerGeneration (CPG)brandnames.
ThisServiceManualprovidesinformationnecessaryfortheservicingofthetransferswitch(es) identifiedonthecoverofthismanual.Thetransitioncapabilitiesofthetransferswitch(es)are identifiedinthefollowingsections.
NOTE:TheServiceManualisintendedtobeusedbyacertifiedCumminsService professional.Theowner/userofthetransferswitchmustNEVERopenthe transferswitchdoor.
Refertotheschematicandwiringdiagrampackagethatwasshippedwiththetransferswitchfor specificinformationabouttheconfiguration.
2.2ModelIdentification
Ifthetransferswitcheverneedstobeserviced,thedistributorwillneedthisinformationinorder toproperlyidentifyyourunitfromthemanytypesmanufactured:
· ModelNo.(ProductModel)
· SerialNo.(ProductSerialNumber)
· Spec.(ProductSpecificationLetter)
A035K570(Issue1) 3
2.Introduction 3-2011
4 A035K570(Issue1)
FIGURE1.TRANSFERSWITCHNAMEPLATE
3Description
3.1ModelOTECE
TABLE1.TRANSFERSWITCHMODELOTECESPECIFICATIONS
3.2FeatureDescriptionsandOptions
TABLE2.FEATUREDESCRIPTIONSANDOPTIONS-OTEC
TransferModes OTECE12001,3R,4,4x,12 PT X OT
ModelAmpsCabinetTypesUtil-to-Gen
FeatureDescription FeatureOption Poles: A028 3-Pole A029 4-Pole AgencyApprovals: A046 ULListing Frequency: A044 60Hertz A045 50Hertz Voltage: R020 120VAC R038 190VAC R021 208VAC R022 220VAC R023 240VAC R024 380VAC R025 416VAC R035 440VAC R026 480VAC R027 600VAC ControlsOptions: J030 ExternalExerciseClock Phase: A041 1Phase,2-Wireor3-Wire A042 3Phase,3-Wireor4-Wire BatteryChargers: K001 2Amp,12/24VDC K002 10Amp,12VDC-Nolongeravailable K003 10Amp,24VDC-Nolongeravailable KB59 15Amp,12VDC KB60 15Amp,24VDC A035K570(Issue1) 5
3.3Utility-to-GeneratorSetOperation
Inutility-to-generatorsetapplications,thetransferswitchperformsthefollowingfunctions:
1.SensestheinterruptionoftheSource1power(Utility).
2.Sendsastartsignaltothegeneratorset(Source2).
3.TransferstheloadtotheSource2power.
4.SensesthereturnofSource1(Utility).
5.RetransferstheloadtoSource1.
6.Sendsastopsignaltothegeneratorset.
3.4Cabinet
CabinetsareavailableinvariousconfigurationsthatmeetULandNationalElectrical Manufacturer'sAssociation(NEMA)requirements.Eachcabinetincludesanidentificationlabel. Thestandardcabinetofferingsare:
· Type1Indoor-generalpurpose
· Type3ROutdoor-rainproof
· Type4Outdoor-watertight
· Type4XOutdoor-watertight,stainlesssteel
· Type12Indoor-dusttight
3.Description 3-2011 FeatureDescription FeatureOption AuxiliaryRelays: L101 24VDCCoil L102 24VDCCoilEmergencyPosition L103 24VDCCoilNormalPosition L201 12VDCCoil L202 12VDCCoilEmergencyPosition L203 12VDCCoilNormalPosition Miscellaneous: M003 TerminalBlock-30Position M032 ElevatorSignalRelay M033 GensetStartingBattery-12VDC M034 GensetStartingBattery-24VDC N002 TerminalBlock-BatteryChargerAlarms Cabinet: B001 Type1 B002 Type3R B003 Type4 B025 Type4X B010 Type12
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3.4.1OTECCabinetComponents
3.5ECControlPanel
TheECcontrolpanelislocatedonthecabinetdoor. Thecontrolfeaturesaredividedintothreegroups: ·
3-2011 3.Description
No. Description No. Description 1 Automatictransferswitch 5 Optionalbatterycharger 2 TB1 6 J1 3 Groundlugs 7 J2 4 TB2
FIGURE2.OTECE1200AMPTRANSFERSWITCHCABINETCOMPONENTS
ControlFunctionLEDs
ATSStatusLEDs
MembranePushbuttons A035K570(Issue1) 7
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3.5.1ControlFunctionLEDs
ThecontrolpanelincludeseightLEDsthatdisplaycodesthatindicatevariouscontrolfunctions thatcanbeconfigured.ThefirstfiveLEDsdisplaythefunctioncodeandthelastthreeLEDs displaythevaluecodeforthedisplayedfunction.
WiththeexceptionofthefirstLED(Test),normallytheseLEDsareoffandareonlylitwhenin ConfigurationMode.TheTestLEDisalsousedtonotifytheuseroftestperiods.
3.5.2ATSStatusLEDs
ThecontrolpanelincludessixLEDsthatprovideAutomaticTransferSwitch(ATS)status information.
UtilityPowerAvailable:ThisgreenLEDislitwhentheutilitypowersourcehasacceptable outputvoltage.
3.Description 3-2011
No.Description No.Description 1ActiveTestLED 7SetExercisepushbutton 2FunctionindicatorLEDs 8ActiveExerciseLED 3UtilityPowerAvailableLED 9GeneratorSetPowerConnectedLED 4Testpushbutton 10GeneratorSetPowerAvailableLED 5UtilityPowerConnectedLED 11ValueindicatorLEDs 6Overridepushbutton
FIGURE3.CONTROLFUNCTIONLEDS
8 A035K570(Issue1)
GensetPowerAvailable:ThisamberLEDislitwhenthegensetpowersourcehasacceptable outputvoltageandfrequency.
BothpowersourceLEDscanbelitsimultaneously.
UtilityPowerConnected:ThisgreenLEDislitwhenutilitypowerissupplyingpowertothe load.
ThisLEDflashesoncepersecondifthereisafailuretoconnecttoordisconnectfromutility power,whencommanded.Thecontrolmakesfiveattempts(thereistensecondsbetweeneach attempt)toconnecttoordisconnectfromutilitypowerbeforeitflashesthefailure.
GensetPowerConnected:ThisamberLEDislitwhenthegensetissupplyingpowertothe load.
ThisLEDflashesoncepersecondifthereisafailuretoconnecttoordisconnectfromthe genset,whencommanded.Thecontrolmakesfiveattempts(thereistensecondsbetweeneach attempt)toconnecttoordisconnectfromthegensetbeforeitflashesthefailure.
Test:ThisamberLEDislitwhenthereisanactivetestperiod.ThisLEDflashestwiceper secondwhentheTestpushbuttonispressedtosetorcancelatestperiod.
Exercise:ThisamberLEDlightswhenrepeatexerciseperiodshavebeenset.ThisLEDflashes twicepersecondwhentheSetExercisepushbuttonispressedtosetorcancelanexercise. ThisLEDflashesoncepersecondduringanactiveexerciseperiod.
3.5.3MembranePushbuttons
Thecontrolpanelincludesthreemembranepushbuttons.
Test:TheTestpushbuttonisusedtosetorcancelatestperiod.Thecontrolcanbeconfigured totestthegensetwithorwithoutload.
NOTE:TheTestpushbuttonisalsousedintheConfigurationModetostepthrough thefunctioncodes.
Override:TheOverridepushbuttonisusedtoterminateorbypasssometimedelays,tostop thePowerConnectedLEDsfromflashingasaresultofafailuretoconnecttoordisconnect fromapowersourceandtocancelanactiveexerciseperiod.
NOTE:TheOverridepushbuttonisalsousedintheConfigurationModetostep throughthevaluecodes.
SetExercise:TheSetExercisepushbuttonisusedtosetorcancelrepeatexerciseperiods usingtheintegratedexerciser.
3.6ElectronicControlSystem
Thissectiondescribesthestandardandoptionalcomponentsoftheelectroniccontrolsystem.
WARNING:Impropercalibrationoradjustmentofelectroniccontrolmodulescancause death,severepersonalinjury,andequipmentorpropertydamage. Calibrationandadjustmentofthesecomponentsmustbeperformedby technicallyqualifiedpersonnelonly.
Forfurtherinformationregardinginstallation,calibrationandadjustmentofthesecomponents, refertothe:
· InstallationManual(shippedwiththeproduct)
3-2011 3.Description
A035K570(Issue1) 9
· ServiceManual(availablethroughyourdistributor)
WARNING:Accidentalactuationofthelinearmotorcouldcauseseverepersonalinjury. Beforemakinganyadjustments,placetheMotorDisconnectSwitchinthe OFFposition.ReturntheswitchtotheAutopositionafteradjustmentsare completed.
WARNING:ACpowerwithinthecabinetandtherearsideofthecabinetdoorpresentsa shockhazardthatcancauseseverepersonalinjuryordeath.Whenthe cabinetdoorisopen,useextremecautiontoavoidtouchingelectrical contactswithbody,tools,jewelry,clothes,hair,etc.
3.6.1TransferInhibit
Atransferinhibitinputissetupbyconnectingadry(voltagefree)contactbetweenTB2-6and TB2-8.Closingthecontactenablesthefeatureandopeningthecontactdisablesit.
FIGURE4.TB2CONNECTIONSFORTRANSFERINHIBIT
Thisfeatureisusedtocontrolloadtransfertogeneratorsets.Whenenabled,loadtransferwill nottakeplaceunlesstheOverridepushbuttononthecontrolpanelispressedorthetransfer inhibitinputisdisabled.
PressingtheOverridepushbuttononthecontrolpanelbypassesthetransferinhibitinputand bypassesTDNE.TheTDNErunsifthetransferinhibitinputisdisabled.
3.Description 3-2011
No.Description No.Description 1GND 5Remotetest 22 6Transferinhibit 3B+ 7Retransferinhibit 4RMT 8Common
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3.6.2RetransferInhibit
Aretransferinhibitinputissetupbyconnectingadry(voltagefree)contactbetweenTB2-7and TB2-8.Closingthecontactenablesthefeatureandopeningthecontactdisablesit.
ThisfeatureisusedtopreventtheATSfromautomaticallytransferringtheloadbacktothe utility.Whenenabled,loadtransferwillnottakeplaceunlesstheOverridepushbuttononthe controlpanelispressed,theretransferinhibitinputisdisabled,orthegensetfails.Ifthegenset fails,retransferinhibitisignored.
PressingtheOverridepushbuttononthecontrolpanelbypassestheretransferinhibitinputand bypassestheTDEN.TheTDNErunsiftheretransferinhibitinputisdisabled.
3.6.3RemoteTestInput
Thetransferswitchmaybewiredforaremotetestinput.Theswitchisusedtostartandstop manuallyinitiatedsystemtests.AswiththecontrolpanelTestpushbutton,theremotetestinput canbeconfiguredtotestwithorwithoutload.
Aremotetestinputissetupbyconnectingadry(voltagefree)contactbetweenTB2-5andTB28.Closingthecontactstartsatestandopeningthecontactcancelsthetest.TheTestLED flashestosignifythestartofatestandstaysonduringthetest.
Closingthecontactcausesthetransferswitchtosensea(simulated)utilitypowerfailureand sendsastart/runsignaltothegenset.Ifthecontrolissetuptotestwithload,theloadis transferredtothegensetwhenthegensetbecomesavailable.TheUtilityPowerAvailableLED remainsontoshowthattheutilitydidnotfail.
3-2011
3.Description
No.Description No.Description 1GND 5Remotetest 22 6Transferinhibit 3B+ 7Retransferinhibit 4RMT 8Common
FIGURE5.TB2CONNECTIONSFORRETRANSFERINHIBIT
A035K570(Issue1) 11
