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
iii
Table of Contents SECTION
5.
(Continued)
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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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
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
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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
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