Page 1

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

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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

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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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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


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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

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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


This Page Intentionally Left Blank

xi


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


FEATURE DESCRIPTION

FEATURE OPTION

Poles: 3 Poles 4 Poles

A028 A029 A035 A036

A044 A045

Auxiliary Relays:

R038 R021 R022 R023 R024 R025 R035 R026 R027

Controls: Level 2 Switch Control

C024

Transfer Mode: Open Transition Programmed Transition Closed Transition

A077 A078 A079

Control Options: Front Panel Security Key Digital Display LONWORKS Network Communications Module Load Monitoring Relay Module Relay−Protective, 62PL Timer, 86 Lock Out Relay−Protective, 62PL Timer, 86 Lock Out, 32R Single Phase Sense Relay−Protective, 62PL Timer, 86 Lock Out, 32R 3 Phase Sense

A041 A042

M017 M018 M020 M022 M023 M045−7

D009

Battery Charges: 2A, 12/24VDC 10 Amp, 12VDC − No Longer Available 10 Amp, 24VDC − No Longer Available 15 Amp, 12 VDC 12 Amp, 24 VDC

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

Digital Bar Graph Meters

A046 A064

Frequency: 60 Hertz 50 Hertz

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

Meters:

Agency Approvals: UL Listing UL/NFPA Listing

FEATURE OPTION

Phase:

Application: Utility to Genset Utility to Utility

FEATURE DESCRIPTION

24 VDC Coil Emergency Position Normal Position Generator Start 12 VDC Coil Emergency Position Normal Position Generator Start

K001 K002 K003 KB59 KB60 L101 L102 L103 L104 L201 L202 L203 L204

Miscellaneous: Terminal Block − 30 Position Load Shed − From Emergency Terminal Block − Battery Charger Alarms Bus Stubs Connection (Open Construction) 4 Ft. Harness Extension (Open Construction)

M003 M007 N002 N009 N013

Cabinet: Type 1 − General use, Indoor Type 3R − Outdoor use Type 4 − Indoor or Outdoor use Open Construction − No Enclosure Type 12 − Indoor, dust-tight and drip-tight Type 4X − Indoor or Outdoor use

M046−7 M047−7

1-4

B001 B002 B003 B004 B010 B025


2. Description This section describes the standard and optional control features as well as the control cabinet and bypass transfer switch.

indoor or outdoor cabinets. Two examples of cabinets, showing interior components are shown in Figures 2-6 and 2-7.

CABINET The standard cabinet meets the requirements of the National Electrical Manufacturers Association (NEMA) for a UL Type 1 cabinet. Cabinets are available in NEMA types 1, 3R, 4, 4X, and 12. The various types are designated as general-purpose,

CONTROL PANEL The panel features are divided into three groups: Bar Graph Meters, Switch Panel and Digital Display (see Figure 2-1). Bar Graph Meters are optional equipment.

P OWER COMMAND BAR GRAPH METER PANEL (OPTIONAL)

SWITCH PANEL KEY SWITCH (OPTIONAL)

DIGITAL DISPLAY

FIGURE 2-1. PORTION OF CABINET WITH OPTIONS

2-1


BAR GRAPH METER PANEL

SWITCH PANEL

The Bar Graph Meter Panel (optional) includes a three phase AC ammeter, a power meter, a power factor meter, a frequency meter, and a three phase AC voltmeter.

The switch panel (Figure 2-3) contains six indicator lamps and three membrane pushbuttons.

AC Ammeter (A−) The ammeter displays the percentage of full load current in amperes (1−125%).

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

FIGURE 2-3. SWITCH PANEL

Power Factor Meter (PF)

Indicator Lamps

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

Source 1 Available and Source 2 Available

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

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

These indicators are lit when the corresponding sources have acceptable output voltage and/or frequency. These indicators can be lit simultaneously. Source 1 Connected This indicator is lit when the transfer switch is in the normal position and Source 1 is supplying power to the load. Source 2 Connected This indicator is lit when the transfer switch is in the emergency position and Source 2 is supplying power to the load. Not in Auto This indicator lights when the transfer switch is not in the Automatic mode of operation and when any of the following signals are active: 

Drawout lever is in the Release Position



Control Mode/Configuration is set to “Offline”



Bypass switch is connected to Normal or Emergency

Test/Exercise Active FIGURE 2-2. BARGRAPH METER PANEL

The Test/Exercise Active indicator is lit when the transfer switch test or exercise operation is active.

2-2


Membrane Pushbuttons Pressing any pushbutton will “wake up� the display panel if it is in a sleep mode.

Digital Display Menu System for complete digital display menu details.

Test For utility-to-genset applications, the Test switch sends a start signal to the generator set designated Source 2 and flashes the Test/Exercise Active indicator. After the start and transfer time delays, Source 2 starts and assumes the load provided the With Load option is enabled. Press the Test switch again to end the test; the Test/Exercise Active indicator goes out and Source 1 resumes as the source of power. Override The Override switch terminates most system time delays. Program Transition, Elevator signal and Engine Cool Down are not affected by this switch. Pressing this switch while the Transfer or Retransfer Inhibit inputs are active, immediately transfers or retransfers the load. Reset/Lamp Test

FIGURE 2-4. DIGITAL DISPLAY

SECURITY KEY SWITCH OPTION The optional security key switch is located on the front panel. When it is in the Panel Lock position, it disables the Test and Override buttons on the front panel. It also prevents changes through the Digital Display to the Setup menus; however, the current values can be viewed. Changes can be made when the key switch is in the Program position (Figure 2-5). The key switch can be disabled in PowerCommand using the InPower service tool.

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

DIGITAL DISPLAY The Digital Display contains a 2-line by 20-character Digital Display Module and 6 momentary contact membrane buttons. The module displays the menu system. The buttons are used to navigate through the menu system. Each menu indicates the function of the four buttons at the sides of the Display Module. Not all buttons are active for each menu. Refer to Section 4:

FIGURE 2-5. KEY SWITCH

InPower is a trademark of Onan Corporation.

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OPTIONAL BATTERY CHARGER

DIGITAL BOARD

SOURCE SELECT SWITCH

BARGRAPH

POWER TRANSFORMER

CONTROL RELAYS

DIGITAL DISPLAY POWER MODULE

BYPASS SWITCH HANDLE

DRAWOUT CRANK HANDLE

FIGURE 2-6. INTERIOR/COMPONENTS − 150−400 AMP SPEC A, 300−600 AMP SPEC B SWITCH

(TYPE 1 CABINET)

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OPTIONAL BATTERY CHARGER

DIGITAL BOARD BARGRAPH

SOURCE SELECT SWITCH

POWER TRANSFORMER

CONTROL RELAYS DIGITAL DISPLAY POWER MODULE

BYPASS SWITCH HANDLE

DRAWOUT CRANK HANDLE

FIGURE 2-7. INTERIOR/COMPONENTS − 600−1000 AMP SPEC A SWITCH (TYPE 3R CABINET)

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BYPASS SWITCH The bypass switch, located behind the automatic transfer switch, is used to open and close the contacts connecting the load to the Normal or Emergency power source. The manually operated bypass switch is mechanically interlocked to prevent simultaneous closing to a dead source or to both power sources at the same time. Operation of the bypass switch is accomplished with the Bypass Switch Handle and the Source Select switch.

SOURCE SELECT SWITCH DRAWOUT RELEASE CONNECTED

DRAWOUT POSITION INDICATOR DRAWOUT LEVER

Contact Assemblies Like the automatic transfer switch, the bypass switch has either three or four poles. Three pole transfer switches are provided with a neutral bar. The contact assemblies are manually actuated to connect the load to one of the two power sources, bypassing the automatic transfer switch. When closed to either the Normal or the Emergency power source, the contacts are mechanically held.

BYPASS SWITCH POSITION INDICATOR

BYPASS SWITCH HANDLE

Auxiliary Contacts

(Open Position)

Auxiliary contacts are provided on the Normal and Emergency sides of the bypass switch. The Normal side auxiliary contact switch is actuated when the bypass switch is in the Normal position. The Emergency side auxiliary contact switch is actuated when the bypass switch is in the Emergency position. The auxiliary contacts have current ratings of 10 amperes at 250 VAC and are wired to terminal block TB1.

DRAWOUT CRANK HANDLE BYPASS SWITCH POSITION INDICATOR

FIGURE 2-8. BYPASS PANEL

The Drawout Position indicator shows which position the automatic transfer switch is in. The drawout mechanism can be latched in one of three positions: Connected, Test, and Isolated (see Figure 2-8).

When the Bypass switch handle is in the Bypass to Normal position, the bypass switch contacts connect the load to the Normal source and the word “Closed” is shown in the Bypass to Normal indicator slot. When the Bypass switch handle is in the Bypass to Emergency position, the bypass switch contacts connect the load to the Emergency source and the word “Closed” is shown in the Bypass to Emergency indicator slot. In both cases, the word “Open” is shown in the opposite indicator slot.

The Bypass to Normal and Bypass to Emergency position indicators show the position of the bypass switch contacts.

When the Bypass switch handle is in the center position, the bypass switch contacts are disconnected from both sources and the word “Open” is shown in both indicator slots.

BYPASS SWITCH CONTROLS Indicators

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Bypass Handle and Select Switch The Source Select Switch is a spring loaded returnto-center, three-position switch used to select the source to bypass. Prior to operating the Manual Bypass handle, this switch must be turned to the source to which the bypass contacts will connect. The Bypass Switch Handle is used in conjunction with the Source Select Switch. The Source Select switch controls an interlock device, which prevents the bypass switch from connecting the load to a dead source or to both sources at the same time. Before operating the Bypass Switch Handle, the Source Select Switch must be turned to the source the load will be connected to. Mechanical and electrical interlocks control the bypass operation. Bypassing to the Same Source: If the automatic transfer switch is already connected to the source to be bypassed, the operator can turn and hold the Source Select switch then move the Bypass Switch Handle, closing the bypass contacts to that same source, without interrupting the load. Bypassing to the Opposite Source: If the automatic transfer switch is NOT already connected to the source to be bypassed, interlocks force the following conditions to be met: 1. The bypass operation is permitted only when the selected source is available. When bypassing to the Emergency source, for example, it is necessary to first check that the Source 2 Available lamp is lit. (Refer to Section 3: Operation.) 2. As the bypass switch handle is moved to the opposite source, electrical and mechanical interlocks force the automatic transfer switch to the neutral position in a break-before-make action. This operation causes a brief power interruption. (Refer to Section 3: Operation.)

DRAWOUT-ISOLATION MECHANISM The drawout-isolation mechanism allows the automatic transfer switch to be isolated for testing or service. Three sets of primary isolation contacts (Normal source, Emergency source, and Load) connect the switching contacts to the terminal

lugs. A set of secondary isolation contacts connects the automatic transfer switch controls to the available power source.

Drawout Cranking Handle The drawout cranking handle is used to isolate and reconnect the automatic transfer switch. The cranking handle turns a gear drive that moves the transfer switch along a mechanically guided path. The cranking handle will operate only when the bypass switch is connected to one of the sources. The operator must lift the drawout lever to deactivate the cranking interlocks. CAUTION Improper usage of the drawout cranking handle can result in equipment damage. Do not use excessive force when operating the handle and do not operate if the bypass switch is not connected to one of the sources.

The Drawout Position Indicator shows the position of the automatic transfer switch. The drawout mechanism can be stopped in one of three positions: Automatic, Test, and Isolate. In the Automatic position, both the primary and the secondary isolation contacts are closed. The automatic transfer switch is in its normal operating position. In the Test position, the primary isolation contacts are open and the secondary isolation contacts are closed. The load-supplying contacts of the automatic transfer switch are out of service, but the controller and linear actuator are powered and fully operational. In this position, the controller, linear actuator, and contact mechanisms can be tested. In the Isolate position, both the primary and the secondary isolation contacts are open. The transfer switch mechanism is completely isolated from both the power and control circuits and can be removed for service. WARNING Improper removal of the automatic transfer switch can cause severe personal injury or death. Removal of the automatic transfer switch must only be performed by trained and experienced personnel, following the procedures provided in the Sections 6 and 7.

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AUTOMATIC TRANSFER SWITCH The automatic transfer switch (Figure 2-9) opens and closes the contacts that transfer the load between the two power sources (1 and 2). The switch is mechanically interlocked to prevent simultaneous closing to both power sources, unless it is a closed transition transfer switch. The main parts of the transfer switch discussed here are the Contact Assemblies, Linear Actuator, Motor Disconnect, and the Auxiliary Contacts.

Contact Assemblies The automatic transfer switch has either three or four poles. Three pole transfer switches are provided with a neutral bar. The contact assemblies make and break the current flow. When closed to either the Normal or the Emergency power source (1 or 2), the contacts are mechanically held. The power contacts are rated at 600 VAC. They are made of a long-life silver alloy which resists burning and pitting, and feature separate arcing surfaces.

Linear Actuator The linear actuators are the operator or motor that moves the contact assemblies between the Normal (Source 1) power and the Emergency (Source 2) power. Linear actuator operation is initiated automatically with automatic transfer switches.

Bypass Source Select Normal

Drawout Release

Emergency

Auxiliary Switches

Drawout Position

Lock

Bypass to Normal OPEN

1

OPEN Bypass to Emergency

AUTOMATIC TRANSFER SWITCH

as

Eight auxiliary switches are configured to respond to the position of the transfer switch. When the transfer switch is in the Source 1 (Normal) position, switches S2, S3, S4, and S5 are actuated. When the transfer switch is in the Source 2 (Emergency) position, switches S6, S7, S8, and S9 are actuated. Refer to Section 5 and to the schematic and wiring diagram package for more information on the functions of the individual switches.

Motor Disconnect

GND

Moving the Drawout Lever to the Release position disables the linear actuators. The Not In Auto indicator on the front panel will light and the display indicates a Motor Disconnect event.

FIGURE 2-9. TRANSFER SWITCHES

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

and drivers for the control panel indicators, switches, and bar graph meter panel. For information on battery maintenance, see Table 3-2.

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

DIGITAL MODULE BATTERIES BAR GRAPH ASSEMBLY OPTIONAL NETWORK COMMUNICATIONS MODULE

NOTE: When making adjustments, do not operate the linear motor more then once every two minutes.

All calibration and adjustment procedures are described in the Installation manual (shipped with the transfer switch). The InPower service tool can be used to create a capture file of all the calibration and adjustment settings in the Digital Module. Refer to the InPower User’s Guide.

NETWORK MODULE BATTERIES DIGITAL MODULE DIGITAL DISPLAY

Accidental actuation of the linear motor could cause severe personal injury. Before making any adjustments, disable the linear actuator. WARNING

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. Use extreme caution to avoid touching electrical contacts whenever the cabinet door is open. Do not wear long hair, damp clothing, or jewelry. Use insulated tools, stand on a dry rubber mat or wood platform and wear safety glasses.

POWER MODULE

FIGURE 2-10. INTERIOR CONTROL COMPONENTS

Electronic Control Circuit Modules

S1 SWITCH BATTERIES J26 J26 J29

J20

The Bypass Transfer Switch PowerCommand (BTPC) transfer switch control incorporates a Digital Module and a Power Module. Power Modules are available in three different voltage ranges. The Digital Module has two 3-volt batteries to power the real-time clock when no source voltage is available. Replace these batteries every two years. Digital Module The Digital Module (Figures 2-10 and 2-11) contains the logic and timing circuits that control transfer switch operation. These modules also contain many customer interface circuits (including the genset start signal and network port), the RS-232 communications port for the InPower service tool,

J24

J28

J25 J27

FIGURE 2-11. LEVEL 2 DIGITAL MODULE

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Power Module The Power Module supplies power to the Digital Module and contains voltage sensing transformers and relays. These modules also hold interface circuits for the transfer switch including position sensing switches and relay drivers. 10 VDC rectification and regulation circuits on this module are powered by both sources through transformers T1 and T2.

CAUTION Improper voltage can result in equipment damage. Replacement Power Modules on all BTPC transfer switches of 1000 amps or less must have jumpers J18 and J19 cut prior to installation.

Control Plate The Control Plate contains two transformers; one for Emergency supply and one for Normal supply (Figure 2-13).

The Power Module contains eight transformers. OPTIONAL BATTERY CHARGER

• Each source (1 and 2) uses three transformers. Source 1 and 2 voltages are sensed by transformers T1 and T2.

POWER TRANSFORMERS

Both sources are connected A:N, B:N and C:N except for 120 volt switches. For 120 volt switches, connect A:N for 2-wire, and AN:CN for 3 wire single phase systems. • The remaining two transformers are used to power the 10 VDC supply on the module. One transformer is connected to Source 1 and the other to Source 2 (Figure 2-12).

CONTROL RELAYS

T7

K3

K4

K5

K6

TO P10

OPTIONAL BATTERY CHARGER

J11 T5

POWER TRANSFORMERS

K12

TB14

K2

SINGLE LINEAR MOTOR

TO J24 ON DIGITAL BOARD

T8

K1

K14

T4

K15

TB12

K13

T6

K16

T3

K17

DANGER

TB13

CONTROL RELAYS

TB11

T1 T2

OPTIONAL LOAD SHED (K7)

FIGURE 2-12. POWER MODULE

Power Modules contain six pilot relays defined as: K12 K13 K14 K15 K16 K17

Neutral to Source 1 Source 2 to Neutral Neutral to Source 2 Source1 to Neutral Not Used Not Used

DUAL LINEAR MOTOR

TO P10

FIGURE 2-13. CONTROL PLATE

On 150−1000 Amp switches, relays K1 through K7 control the opening and closing of various switches.

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Single Linear Motor (Open Transition): K1 K2 K3 K4 K5 K6 K7

Transfer to Normal Transfer to Emergency Programmed Transition Optional Load Shed Bypass to Normal Bypass to Emergency Not Installed

Dual Linear Motor (Closed Transition): K1 K2 K3 K4 K5 K6 K7

Open Emergency Open Normal Close Emergency Close Normal Bypass to Normal Bypass to Emergency Optional Load Shed

The Source 1 or Source 2 Available relays are energized when their respective power sources are producing power. The Test/Exercise relay is energized when the system is in test or exercise mode. The Elevator Pre-Transfer relay is energized during the elevator signal time delay. The relay contacts are used to provide a warning that a transfer or retransfer is about to occur. This time delay (TDEL) is adjustable over a range of 0 to 60 seconds. The default value is 0 seconds. The value is set with the InPower Service tool or the digital display (see page 4-18 or page 4-19, depending on software version) when it is available.

 TDEL

Connectors P1 and P10 are the interface and power sources for the cabinet door, the bypass switch and the transfer switch.

 0.0 Seconds

Two-Wire Starting The starting circuit is a basic supervisory function of the electronic control. Water-cooled generator sets use a two-wire start control. Although the logic is more involved, the two-wire starting circuit can be thought of as a single pole, single throw switch. A closed switch starts the generator set. An open switch stops the generator. Three-wire starting is not available on BTPC transfer switches.

ELECTRONIC CONTROL OPTIONS Relay Module Option The Relay Module (see Figure 2-15) provides nine sets of Form-C contacts and two sets of normally open contacts that are rated for 2 Amps at 30 VDC or 0.60 Amps at 120 VAC. Connections to these relays are made at J14 and J15 on the Relay Module. The Relay Module is located on the left inside wall of the transfer switch enclosure. See Table 2-1 for relay module connections. The Source 1 or Source 2 Connected relays are energized when their respective power sources are available, ready to produce power, and connected to the load. These relays are latching relays and will retain their last state in case of a complete loss of power.



FIGURE 2-14. TDEL SUB-MENU

The Fail to Transfer/Retransfer relay is energized whenever the transfer switch does not open or close within a set time interval after the command to transfer or retransfer. The Fail to Synchronize relay is energized when the two power sources did not come into synchronicity (frequency, voltage, phase) within a two-minute limit, during a transfer between two live sources. The Fail to Disconnect fault is used only in closed transition modes. The relay is energized whenever the two sources remain parallel longer than a set time limit (100 milliseconds). The ATS Not-In-Auto relay is energized when any one of the following occurs: • The drawout release lever is lifted • Fail-to-Disconnect event is active • Wiring harness is disconnected from J12 on the Power Module • Controller is set to Offline The Load Shed relay is active when the transfer switch has been commanded to disconnect the load from power Source 2. Use number 22 to number 12 AWG wire. For connection to the screw terminal, strip the insulation back 3/8 inch (10 mm).

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Cummins onan btpcb transfer switch 150 1000 amperes service repair manual  
Cummins onan btpcb transfer switch 150 1000 amperes service repair manual  
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