Service Manual
Transfer Switch 150−1000 Amperes
BTPCB (Spec A) BTPCC (Spec A−B) BTPCD (Spec A)
English
10−2009
962−0518 (Issue 6)
Table of Contents SECTION
TITLE
PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ix
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Switch Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drawout Isolation Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility-to-Genset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility-to-Utility Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and Replacing Electronic Control Components . . . . . . . . . . . . . . . . . . Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-3 1-3
2. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bar Graph Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Ammeter (A−) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Meter (kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Factor Meter (PF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Meter (Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Voltmeter (V−) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source 1 Available and Source 2 Available . . . . . . . . . . . . . . . . . . . . . . . . . . Source 1 Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source 2 Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not in Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test/Exercise Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Membrane Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset/Lamp Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1 2-1 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-2 2-3 2-3 2-3 2-3
Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Security Key Switch Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Switch Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Handle and Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3 2-3 2-6 2-6 2-6 2-6 2-6 2-7
i
SECTION
TITLE
PAGE
Drawout-Isolation Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drawout Cranking Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Circuit Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Linear Motor (Open Transition): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Linear Motor (Closed Transition): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-Wire Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Module Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Test Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charger Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original Float Battery Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Float Battery Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-Amp Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/12-Amp Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PowerCommand Network Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7 2-7 2-8 2-8 2-8 2-8 2-8 2-9 2-9 2-9 2-10 2-11 2-11 2-11 2-11 2-11 2-13 2-13 2-13 2-14 2-14 2-15 2-15 2-16 2-18 2-18
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Functional Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transition Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Open Transition with Sync Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmed Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Closed Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 3-1 3-1 3-1 3-1
Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Engine Start (TDESa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Engine Cooldown (TDECa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Normal to Emergency (TDNE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Emergency to Normal (TDEN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmed Transition Time Delay (TDPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elevator Time Delay (TDEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Average Transfer Time(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Undervoltage Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overvoltage Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Imbalance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 3-2 3-2 3-2 3-3 3-3 3-3 3-3 3-4 3-4 3-5 3-6 3-7
ii
SECTION
TITLE
PAGE
Phase Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loss of Single Phase Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sync Check Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Active Sync Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Tests, Exercises, and Exercise Exceptions . . . . . . . . . . . . . . . . . . . . . . Testing 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) − For Software Versions Prior to 1.5.190 . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypassing the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypassing Load to Normal (Source 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypassing Load to Emergency (Source 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolating the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reconnecting the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load is Bypassed to the Normal Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Start Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With Load Standby Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Load Break Transfer Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power System Functional Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weekly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Monthly Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annual Maintenance and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clean and Inspect the Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annual Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7 3-8 3-8 3-9 3-9 3-10 3-10 3-10 3-10 3-10 3-11 3-12 3-12 3-14 3-15 3-16 3-17 3-18 3-18 3-19 3-19 3-19 3-19 3-20 3-20 3-21 3-21 3-21 3-22 3-23 3-23 3-23 3-23 3-23 3-23 3-24 3-24
4. DIGITAL DISPLAY MENU SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Previous Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source 1 and Source 2 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 4-1 4-1 4-2 4-2 4-3 4-4
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TITLE
PAGE
Load Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Statistics Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Events Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Menu Navigation and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Versions Prior to Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor 1 & Sensor 2 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Versions Prior to Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sync Check Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Versions Prior to Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exerciser Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Software Versions Prior to 1.5.190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.5.190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exercise Exceptions Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.5.190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.13.244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.13.244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clock Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequencer Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Active TD Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. EVENTS .
4-5 4-6 4-6 4-7 4-8 4-9 4-10 4-11 4-11 4-12 4-13 4-13 4-15 4-17 4-18 4-18 4-19 4-20 4-21 4-21 4-23 4-25 4-25 4-27 4-29 4-31 4-33 4-35 4-35 4-35 4-36 4-37 4-38 4-38 4-40 4-42 4-43 4-43 4-44
5-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATS Common Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charger Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
5-1 5-1 5-1 5-1 5-1
SECTION
TITLE
PAGE
Common Alarm A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Alarm B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Start A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exercise Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fail to Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fail to Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fail to Retransfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fail to Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Neutral Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Wink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not in Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Panel Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Rotation Fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retransfer Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1 Failed to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1 Failed to Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1 Frequency Fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1 Imbalance Fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1 Loss Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S2 Failed to Close . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S2 Failed to Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S2 Frequency Fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S2 Imbalance Fail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S2 Loss Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S2 Over Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S2 Stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S2 Under Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequencer Output 1 thru Sequencer Output 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source-1 Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source-1 Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source-2 Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source-2 Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sync Check Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sync Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDECa (Time Delay Engine Cool-Down (A)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDEL (Transfer Pending) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDEN (Time Delay Source 2 (E) to Source 1 (N)) . . . . . . . . . . . . . . . . . . . . . . .
v
5-1 5-1 5-1 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 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 5-6 5-6 5-6 5-6 5-6
SECTION
TITLE
PAGE
TDESa (Time Delay Engine Start A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TDNE (Time Delay Source 1 (N) to Source 2 (E)) . . . . . . . . . . . . . . . . . . . . . . . TDPT (Time Delay Programmed Transition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test In Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Start A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Inhibit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6 5-6 5-7 5-7 5-7 5-7
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Event Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Checksum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Controller Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATS Fail to Close: Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATS Fail to Close: Re-Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charger Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Battery Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Communications Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting with Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1 6-1 6-2 6-2 6-2 6-2 6-2 6-3 6-3 6-4 6-5 6-5 6-5 6-8 6-8 6-8 6-8 6-8 6-8 6-8 6-8 6-9 6-9
7. AUTOMATIC TRANSFER SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Membrane Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup with a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Without a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After the Setup is Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass and Isolate the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the Automatic Transfer Switch (When Finished) . . . . . . . . . . . . . . . . Reconnecting the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1 7-1 7-2 7-3 7-3 7-3 7-3 7-3 7-6 7-6 7-6 7-7 7-7
vi
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TITLE
PAGE
Linear Actuator Removal and Replacement (150-225-260 Amperes) . . . . . . . . . 7-8 Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8 Block and Cross-Bar Assembly Removal and Replacement (150-225-260 Amperes) 7-11 Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . 7-11 Replacing Block and Cross-Bar Assembly (Normal or Emergency) . . . . . . . . 7-14 Auxiliary Switch Removal and Replacement (150-225-260 Amperes) . . . . . . . . 7-15 Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Linear Actuator Removal and Replacement (300-400 Amperes Spec A and 300−600 Amperes Spec B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Block and Cross-Bar Assembly Removal and Replacement (300-400 Amperes Spec A and 300-600 Amperes Spec B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . 7-19 Replacing Block and Cross-Bar Assembly (Normal or Emergency) . . . . . . . . 7-22 Auxiliary Switch Removal and Replacement (300−400 Amperes Spec A and 300−600 Amperes Spec B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Linear Actuator Removal and Replacement (600-800-1000 Amperes Spec A) . 7-24 Removing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Replacing Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Block and Cross-Bar Assembly Removal and Replacement (600-800-1000 Amperes Spec A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . 7-27 Replacing Block and Cross-Bar Assembly (Normal or Emergency) . . . . . . . . 7-30 Auxiliary Switch Removal and Replacement (600-800-1000 Amperes Spec A) 7-31 Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Mis-Wired Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 8. BYPASS SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
Bypass, Isolation, and Removal Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Remove the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Disconnect AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Reconnect AC Power and Install and Reconnect the Automatic Transfer Switch . . . . 8-1 Installing the Automatic Transfer Switch (When Finished) . . . . . . . . . . . . . . . . 8-2 Reconnecting the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 Block and Cross-Bar Assembly Removal and Replacement (150-225-260 Amperes) 8-2 Removing the Block and Cross-Bar Assembly (Normal or Emergency) . . . . . 8-3 Replacing Block and Cross-Bar Assembly (Normal or Emergency) . . . . . . . . 8-7 Auxiliary Switch Removal and Replacement (150-225-260 Amperes) . . . . . . . . 8-8
vii
SECTION
TITLE
PAGE
Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 Block and Cross-Bar Assembly Removal and Replacement (300-400 Amperes Spec A and 300-600 Amperes Spec B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10 Removing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . 8-10 Replacing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . 8-14 Auxiliary Switch Removal and Replacement (300-400 Amperes Spec A and 300-600 Amperes Spec B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15 Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Block and Cross-Bar Assembly Removal and Replacement (600-800-1000 Amperes Spec A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16 Removing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . 8-17 Replacing the Block and Cross-bar Assembly (Normal or Emergency) . . . . . 8-22 Auxiliary Switch Removal and Replacement (600-800-1000 Amperes Spec A) 8-23 Removing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23 Replacing Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24 9. PROTECTIVE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
10.SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Schematic PAG E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 POWER MODULE (PIN-OUTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 POWER MODULE AC POWER CONNECTIONS (PIN-OUTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 DIGITAL MODULE (PIN-OUTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 Typical Interconnection Diagram (Sheet 1 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Typical Interconnection Diagram (Sheet 2 of 10) . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Typical Interconnection Diagram (Sheet 3 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11 Typical Interconnection Diagram (Sheet 4 of 10) . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Typical Interconnection Diagram (Sheet 5 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Typical Interconnection Diagram (Sheet 6 of 10) . . . . . . . . . . . . . . . . . . . . . . . . 10-14 Typical Interconnection Diagram (Sheet 7 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Typical Interconnection Diagram (Sheet 8 of 10) . . . . . . . . . . . . . . . . . . . . . . . . 10-16 Typical Interconnection Diagram (Sheet 9 of 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Typical Interconnection Diagram (Sheet 10 of 10) . . . . . . . . . . . . . . . . . . . . . . . 10-18 Typical Wiring Diagram (Sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 Typical Wiring Diagram (Sheet 2 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Typical Wiring Diagram (Sheet 3 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Typical Wiring Diagram (Sheet 4 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22 Typical Wiring Diagram (Sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23 125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 1 of 5) . . 10-24
viii
SECTION
TITLE
PAGE
125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 2 of 5) . . 10-25 125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 3 of 5) . . 10-26 125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 4 of 5) . . 10-27 125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 5 of 5) . . 10-28 Power Module 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Typical Interconnect Diagram − Genset to Genset, Plant to Plant . . . . . . . . . 10-30 Typical Interconnect Diagram − Genset to Genset, Dual Stand-By System . 10-31 M045 − Protective RElay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 M045 PROTECTIVE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 M046/M047 − Protective RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 M046/M047 PROTECTIVE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 M046/M047 − Protective RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 M046/M047 PROTECTIVE RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
ix
Safety Precautions UTILITY-TO-GENSET OR GENSET-TOGENSET APPLICATIONS
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.
If the cabinet must be opened for any reason: 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.
2. Disconnect the battery charger. 3. 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.
4. Remove AC power to the automatic transfer switch. If the instructions require otherwise, use extreme caution due to the danger of shock hazard.
CAUTION This symbol refers to a hazard or unsafe practice that can result in personal injury or product or property damage.
UTILITY-TO-UTILITY APPLICATIONS
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH
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.
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.
GENERAL PRECAUTIONS 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.
Whenever the bypass switch is in the Emergency position, an auxiliary switch closes a set of normally open contacts to provide a constant generator set start/run signal. The transfer switch, the emergency bus, and the load bus are energized by the output of the generator set and present a serious shock hazard whenever the bypass switch is in the Emergency position.
WARNING
INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH, SEVERE PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.
BTPC-2
x
1. Introduction ABOUT THIS MANUAL
TRANSFER SWITCH APPLICATION
This manual contains service procedures for Bypass Transfer Switch PowerCommand (BTPC) automatic transfer switches (ATS) rated at 150−1000 amperes and 300−600 amperes. This manual provides information on the following transfer switch models.
The BTPC transfer switch combines an automatic transfer switch, a manual bypass switch and a drawout isolation mechanism in one unit.
BTPC transfer switches are open transition transfer switches. With an open transition switch there is never a time when both sources are supplying power to the load. BTPC transfer switches are capable of executing Open Transition with Sync Check, Programmed Transition, and Closed Transition transfer modes. An Open Transition with Sync Check Transfer Mode executes an open transition when both sources of power are within specified tolerances of frequency, voltage, and relative phase difference. If both sources meet the tolerances, a fast transfer occurs.
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. 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 (illustrated as Normal). If Source 1 is interrupted, the load is transferred to Source 2 (Emergency). 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 the ATS. SOURCE 1 (NORMAL)
A Programmed Transition Transfer Mode executes an open transition by disconnecting the load from the source of power, pausing in the neutral position of the transfer switch (between switched positions) to allow transient currents from the load to diminish, and then the load is switched to the other source.
ISOLATING CONTACTS
A Closed Transition Transfer Mode executes a load transfer by momentarily paralleling both sources (a maximum of 100ms) before switching sources.
ES1968
BYPASS TRANSFER SWITCH
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. PowerCommand is a registered trademark of Onan Corporation. Onan and Cummins are registered trademarks of Cummins Inc.
SOURCE 2 (EMERGENCY)
LOAD
AUTOMATIC TRANSFER SWITCH
FIGURE 1-1. BTPC TRANSFER SWITCH (TYPICAL 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.
1-1
Bypass Switch Function The bypass switch allows the operator to manually connect the load to the available power source, bypassing the automatic transfer switch (Figure 1-1). When bypassed, the automatic transfer switch can be isolated for service or removal without causing a power interruption.
Drawout Isolation Mechanism The drawout isolation mechanism allows the automatic transfer switch to be withdrawn for testing or service. The transfer switch is mounted on rails and is connected to the load, power sources, and controls through isolation contacts. Turning a drawout cranking handle moves the automatic transfer switch along the rails and engages and disengages the isolation contacts to permit testing or service. If necessary, the switch can be lifted from its rails and removed for service.
preferred source. The control automatically transfers the load between the two utilities and detects alarm conditions. The exercise routine is not available in this configuration. 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 4-17). The PC service tool can also be used to designate either source as the preferred source.
Preferred Source
Source 1/Source 2
FIGURE 1-2. PREFERRED SOURCE SUBMENU
UTILITY-TO-GENSET OPERATION In utility-to-genset applications, the transfer switch performs the following functions:
REMOVING AND REPLACING ELECTRONIC CONTROL COMPONENTS
2. Sends a start signal to the generator set (Source 2).
WARNING 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. Disconnect connector J10/P10 before working on the electronic control system.
3. Waits for the voltage to stabilize and then transfers the load to the Source 2.
Disconnecting J10/P10 removes all power to the door.
1. Senses the interruption of the Source 1 power.
4. Senses the return of Source1. 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. Senses the interruption of the Source 1 power. 2. Transfers the load to the Source 2. 3. Senses the return of Source 1. 4. Retransfers the load to Source 1. The controller can control a two-utility configuration for prime power. One utility is designated the
Be sure to remove all power before replacing electronic control modules and components. This includes removing one of the lithium batteries from the Digital Module. Reinstall the lithium battery after performing service parts replacement. No special tools are required to remove and replace control system components. Be sure to use all of the hardware when remounting components. Refer to “Power Module Test� on page 6-2 for special instructions when replacing the power modules. If possible, use the InPower service tool to create a capture file of the calibration and adjustment settings in the Digital Module. Use the capture file to write these settings to a replacement Digital Module.
InPower is a trademark of Onan Corporation.
1-2
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. Feature/option codes are listed on the following page. The model number is made up of code segments that designate various features or options: BTPCB00000 | | | 1 2 3
Spec. A | 4
4. Specification Letter − advances with production modification.
HOW TO OBTAIN SERVICE When the transfer switch requires servicing, contact your nearest Cummins Power Generation distributor. Factory-trained Parts and Service representatives are ready to handle all your service needs. To contact your local Cummins Power Generation (CPG) distributor in the United States or Canada, call 1-800-888-6626 (this automated service utilizes touch-tone phones only). By selecting Option 1 (press 1), you will be automatically connected to the distributor nearest you. If you are unable to locate a dealer or distributor, consult the Yellow Pages. Typically, distributors are listed under: Generators-Electric, Engines-Gasoline or Engines-Diesel, or Recreational Vehicles-Equipment, Parts and Service.
1. BTPC − Bypass Transition PowerCommand Control. 2. Ampere Rating: B = 150−260 C = 300−400 (Spec A) C = 300−600 (Spec B) D = 600−1000 (Spec A)
For outside North America, call Cummins Power Generation, 1-763-574-5000, 7:30 AM to 4:00 PM, Central Standard Time, Monday through Friday. Or, send a fax to Cummins Power Generation using the fax number 1-763-528-7290.
3. Assigned Spec Number − issued for each specific combination of accessories, voltages, frequency and standards codes.
When contacting your distributor, always supply the complete Model Number and Serial Number as shown on the nameplate.
1-3