Service Manual
Transfer Switch 1200−4000 Amperes
WOTPCE (Spec A) WOTPCF (Spec A) WOTPCG (Spec A) WOTPCH (Spec A) WOTPCJ (Spec A)
English − Original Instructions
3-2010
A030R452 (Issue 1)
Table of Contents SECTION 1.
2.
TITLE
PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VII
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 Level 1 and Level 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 1-8 1-8
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retransfer Inhibit Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Relays Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Module Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PowerCommand Network Interface Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 2-7 2-7 2-8 2-9 2-9 2-9 2-9 2-10 2-10 2-11 2-11 2-12 2-14
i
Table of Contents SECTION
3.
(Continued)
TITLE
PAGE
Load Current and Power Sensor Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Shed Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Sequencing Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and Replacing Electronic Control Components . . . . . . . . . . . . . . . . . .
2-15 2-17 2-17 2-18 2-18 2-18 2-18 2-18 2-18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Functional Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transition Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer/Re-Transfer Inhibits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmed Transition Time Delay (TDPT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elevator Time Delay (TDEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Under-Voltage Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over-Voltage Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Imbalance Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Rotation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loss of Single Phase Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sync Check Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Tests, Exercises, and Exercise Exceptions . . . . . . . . . . . . . . . . . . . . . . Test With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmable Generator Set Exercises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Start Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With-Load Standby System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 3-4 3-5 3-6 3-7 3-7 3-7 3-8 3-9 3-9 3-9 3-10 3-10 3-15 3-15 3-15 3-15 3-16 3-17
ii
Table of Contents SECTION
(Continued)
TITLE
PAGE
Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 4.
5.
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 . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . .
4-1 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 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 5-1 5-1 5-1 5-1 5-2 5-2 5-2
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TITLE
PAGE
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . . . . . . . . . . .
iv
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 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
Table of Contents SECTION
6.
7.
(Continued)
TITLE
PAGE
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5 5-5 5-6 5-6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1
Transfer Switch Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . InPower Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Network Applications and Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . Digital Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control LED Indicators and Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exercise Enable/Disable Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer from Source 1 to Source 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer from Source 2 to Source 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibrating the Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Using Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Flash-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Event Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Checksum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures for Transfer Switches with Electro-Mechanical Control Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2 6-3 6-3 6-3 6-3 6-4 6-4 6-4 6-5 6-6 6-6 6-7 6-8 6-8 6-8 6-10 6-10 6-10 6-10 6-10 6-10 6-10 6-11 6-11
TRANSFER SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and Replacing Electronic Control Components . . . . . . . . . . . . . . . . . . Membrane Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1 7-1 7-1 7-3 7-3 7-4 7-5 7-5
v
6-11
Table of Contents SECTION
(Continued)
TITLE
PAGE
Setup with a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Without a Capture File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After the Setup is Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Switch Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnect AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reconnecting AC Power (When Finished) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Actuator Solenoid Removal and Replacement (1200 − 4000 Amperes) . Removing Actuator Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Actuator Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Assembly Removal and Replacement (1200 Amperes) . . . . . . . . . . . . . Removing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Movable and Contact Assembly Removal and Replacement (1600 − 2000 Amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Movable and Contact Assembly Removal and Replacement (3000 Amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Switch Removal and Replacement (1200 - 4000 Amperes) . . . . . . . . . Removing and Replacing an Auxiliary Switch Assembly . . . . . . . . . . . . . . . . . . Mis-Wired Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-16 7-16 7-18 7-20 7-20 7-21
8.
PROTECTIVE RELAY OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1
9.
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1
vi
7-5 7-5 7-5 7-8 7-8 7-8 7-9 7-9 7-10 7-10 7-10 7-11 7-14 7-14 7-15
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. 2. Disconnect the starting batteries of the generator set or sets (remove the ground [−] lead first).
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.
This symbol refers to a hazard or unsafe practice that can result in severe personal injury or death. WARNING
CAUTION This symbol refers to a hazard or unsafe practice that can result in personal injury or product or property damage.
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH 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.
UTILITY-TO-GENSET OR GENSET-TO-GENSET APPLICATIONS If the cabinet must be opened for any reason:
UTILITY-TO-UTILITY APPLICATIONS 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.
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 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.
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.
vii
1. Introduction ABOUT THIS MANUAL
switches the electrical load from one source to the other.
This manual provides information necessary for operation of an WOTPC automatic transfer switch (ATS). This transfer switch and it is equipped with PowerCommand® Control (PC) and it is capable of executing Open Transition with Sync Check, Programmed Transition, and Closed Transition transfer modes.
The load is connected to the common of the transfer switch (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 transfer switch.
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.
POWER 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.
OVERCURRENT PROTECTIVE DEVICE
A Closed Transition Transfer Mode executes a load transfer by momentarily paralleling both sources (a maximum of 100ms) before switching sources. LOAD
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 section 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.
OVERCURRENT PROTECTIVE DEVICE
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
POWER SOURCE 2 (EMERGENCY) FIGURE 1-1. LOAD TRANSFER SWITCH (TYPICAL FUNCTION)
Copyright© 2006 Cummins Power Generation. All rights reserved. Cummins, Onan, and PowerCommand are registered trademarks of Cummins Inc.
1-1
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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
GENERATOR-TO-GENERATOR OPERATION
UTILITY-TO-GENSET OPERATION
In genset-to-genset applications, there are two possible configurations, as shown in Figure 1-3.
In utility-to-genset applications, the transfer switch performs the following functions:
• 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.
1. Senses the interruption of the Source 1 power. 2. Sends a start signal to the generator set (Source 2).
In Prime Power genset-to-genset applications, the ATS performs the same as with utility-to-genset applications.
3. Transfers the load to the Source 2. 4. Senses the return of Source 1.
In Dual Standby gen-to-gen applications, the master and the slave ATSs perform the following functions.
5. Retransfers the load to Source 1. 6. Sends a stop signal to the generator set.
1. The slave ATS begins connected to the preferred source (either genset A or B, but neither genest 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.
UTILITY-TO-UTILITY OPERATION In utility-to-utility applications, the transfer switch performs the following functions: 1. Monitors the primary (Source 1) power. 2. Senses the interruption of the Source 1 power.
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.
3. Transfers the load to the Source 2. 4. Senses the return of Source 1. 5. Retransfers the load to Source 1. 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.
5. When the Stand-by Signal is disabled, the slave ATS turns off the operating genset (either genset A or B). NOTE: The Test/Exercise function and Load Shed feature are 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 4-13). The PC service tool can also be used to designate either source as the preferred source.
Prime Power (Plant to Plant) Operation In prime power applications, utility power is not available. The system includes one transfer switch 1-2
and two gensets (see Figure 1-3). One genset is always running and supplying power to the load while the other genset is the backup genset. An external power supply is not needed in this application.
At any time, the PC service tool or the Test submenu (see Figure 1-2) can be used to designate either genset (Source 1 or Source 2) as the preferred genset. The Preferred Source menu is included in the Test submenus (see Figure 4-13).
Preferred Source Selection
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.
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. GENSET B
GENSET B
OVERCURRENT PROTECTIVE DEVICE
UTILITY OVERCURRENT PROTECTIVE DEVICE
MASTER ATS STAND-BY START LOAD
SLAVE ATS
LOAD
OVERCURRENT PROTECTIVE DEVICE OVERCURRENT PROTECTIVE DEVICE GENSET A
OVERCURRENT PROTECTIVE DEVICE GENSET A
GEN-TO-GEN CONFIGURATION IN PRIME POWER MODE
GEN-TO-GEN CONFIGURATION IN DUAL STANDBY MODE
Figure 1-3. Generator-to-Generator Configuration in Prime Power and Dual Standby Modes
1-3
1. Place the motor disconnect switch in the Off position, and both generator selector switches into the OFF position.
Automatic Changeover The transfer switch can be set up to change the preferred source automatically by enabling the changeover timer. The Time Delay submenus under Setup (see Figure 4-12) or the PC service tool can be used to enable the changeover timer and specify a changeover delay time period (see Figure 1-4). The Changeover menus are included in the Time Delay submenus.
2. Place the transfer switch in the Source 1 position. 3. Place the Off−Manual−Auto selector switch on the Source 1 genset control in the Auto position. The genset will start and supply power to the load (the load will be energized and TDEC may be timing).
The automatic changeover timer automatically changes the preferred source and transfers the load to the new preferred genset after a TDEN time delay. After the transfer is complete, the control initiates a cool-down period (TDEC) on the old preferred genset before shutting it down. The old preferred genset is now the new backup genset. The changeover timer is now timing for the next changeover and the cycle continues as long as the changeover timer is enabled.
4. Use the PC Service tool or the Test submenu to set this genset as the preferred source. 5. Wait for TDECa to finish timing. 6. Place the Off−Manual−Auto selector switch on the Source 2 genset control in the Auto position. 7. Place the motor disconnect switch in the Auto position. 8. If desired, use the Time Delay submenus under Setup or use the PC Service tool to enable the changeover timer and specify a changeover delay time period.
Changeover Enable
Enabled/Disabled
Testing the System by Turning Off the Preferred Source
CHANGEOVER ENABLE/DISABLE
1. With the preferred source genset running and supplying power to the load, place the genset control Off−Manual−Auto selector switch in the Off position. The backup genset should start and run.
Changeover Delay
24 Hours
CHANGEOVER TIME DELAY
Level 2 Controllers Only
After the voltage and frequency are at acceptable levels, the transfer switch should transfer the load to the backup genset.
FIGURE 1-4. CHANGEOVER SUBMENUS
2. Place the genset control Off−Manual−Auto selector switch on the preferred genset back in the Auto position. The preferred genset should start and run.
Prime Power Wiring A permanent start jumper is installed in the transfer switch and is shipped from the factory in the prime power mode. Verify that the jumper (TB3-57 to TB3-59) is installed (see interconnect drawing 626−2108, sheet 3 in Section 9).
After the voltage and frequency levels are at acceptable levels, the transfer switch should transfer the load back to the preferred genset. After the transfer is complete, the control initiates a cool-down period (TDEC) on the backup genset and it should stop.
System Startup To set up a system for prime power operation:
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Testing the System by Changing the Designated Preferred Source
If the Stand-By Start is inactive, upon initial power– up (or reset), or during software initialization, the transfer switch control will not start either genset. When a Stand-by Start command is received by the Slave ATS from a Master ATS (or other device), the preferred genset immediately starts. If the preferred genset does not start, a time delay engine start (TDES) is initiated and the control starts the backup genset. The load is connected to the genset when it becomes available.
1. With the preferred source genset running and supplying power to the load, use the PC service tool or the Test submenu to change the preferred source. The new preferred source should start and run. After the voltage and frequency are at acceptable levels, the transfer switch should transfer the load to the new preferred source.
If the preferred genset becomes available while the backup genset is active, a time delay retransfer (TDEN) period is initiated and the load is retransferred back to the preferred genset. A time delay cool-down (TDEC) period is initiated before turning off the backup genset. When the Stand-by Start signal becomes deactivated, a TDEC period is initiated and the active generator is turned off.
After the transfer is complete, the control initiates a cool-down period (TDEC) on the old preferred source and it should stop.
2. Use the PC service tool or the Test submenu to change the preferred source back to the original genset. The original genset should start and run.
Preferred Source Selection Under normal operation, one genset is designated as the preferred source and the second genset is designated as the backup power source. If both the utility power and the preferred genset fails, the backup genset starts and the gen-to-gen transfer switch transfers the load to the backup genset.
After the voltage and frequency levels are at acceptable levels, the transfer switch should transfer the load back to the original genset. After the transfer is complete, the control initiates a cool-down period (TDEC) on the backup genset and it should stop.
At any time, the PC service tool or the Test submenu (see Figure 4-13) on the gen-to-gen ATS can be used to designate either genset (Source 1 or Source 2) as the preferred genset. If the preferred genset is changed and the backup genset becomes the preferred genset, the ATS transfers the load to the new preferred genset if it is needed and when it becomes available.
Dual Stand-By Operation In dual stand-by applications, utility power is available. The system includes two transfer switches (a Master ATS and a Slave ATS) and two gensets (see Figure 1-3). Utility power supplies power to the load and both gensets are backup gensets.
Alternating Preferred Source
Under normal operation, the utility is supplying power to the load through the master transfer switch. The master transfer switch is a utility-togenset switch. The two gensets are connected to the gen-to-gen slave ATS. The load side of this switch is connected to the genset side of the master transfer switch.
In an attempt to keep the running time equally distributed between both gensets, the control can be set to alternate between the gensets when utility power fails. The selected preferred genset starts with the first power outage. The second power outage starts the backup genset, which now becomes the preferred genset. Upon subsequent outages, the preferred genset alternates.
Upon loss of utility power to the master ATS, a Stand-by Start signal is sent to the gen-to-gen ATS to start the preferred genset. When the master transfer switch senses generator voltage, it transfers the load to that genset. If the preferred genset fails to start, a signal is sent to the backup genset to start. The PC service tool or the Test submenu on the gen-to-gen ATS can be used to set the preferred source.
Utility outages, tests, or exercises initiated at the master transfer switch result in the gensets being alternated. The designated preferred genset will not change if it fails and the backup genset takes over the load. This alternating preferred source can only be enabled with the PC service tool. When enabled, a genset can be designated as the preferred source for a maximum of two weeks. 1-5