Service Manual
Transfer Switch 1200−4000 Amps
BTPC
English
3-2008
962−0519 (Issue 3)
Table of Contents SECTION
TITLE
PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vi
1.
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Switch Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bypass Switch Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drawout Isolation Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility-to-Genset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility-to-Utility Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and Replacing Electronic Control Components . . . . . . . . . . . . . . . . . . . Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3
2.
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Bar Graph Meter Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Pushbuttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Bypass Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Bypass Switch Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Drawout-Isolation Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Drawout Cranking Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Linear Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Motor Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Electronic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Electronic Control Circuit Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Digital Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 System Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Two-Wire Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
i
Table of Contents SECTION
(Continued)
TITLE
PAGE
Transfer Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing With or Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Exercise Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Test Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charger Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Original Float Battery Charger Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Float Battery Charger Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-Amp Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/12-Amp Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Security Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PowerCommand Network Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10 2-10 2-11 2-11 2-11 2-11 2-12 2-13 2-13 2-13 2-13 2-14 2-14 2-15 2-17 2-17 2-17
3.
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transfer to Source 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transfer to Source 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Start Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With Load Standby Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Load Break Transfer Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 3-1 3-2 3-2 3-2 3-3 3-4 3-5 3-5 3-6 3-6 3-6 3-6 3-7 3-8
4.
DIGITAL DISPLAY MENU SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using the Previous Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1 4-1 4-1 4-1 4-2 4-2
ii
Table of Contents SECTION
(Continued)
TITLE
PAGE
Main Menu Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source 1 and Source 2 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Statistics Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prior to Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3 4-4 4-5 4-6 4-6
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Events Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Setup Menu Navigation and Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Changing Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Software Versions Prior to Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Sensor 1 & Sensor 2 Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Software Versions Prior to Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Sync Check Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Time Delay Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Software Versions Prior to Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Test Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Exerciser Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Software Versions Prior to 1.5.190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21
Starting with Software Version 1.5.190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Exercise Exceptions Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Starting with Software Version 1.5.190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-25
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-27
Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-29
Starting with Software Version 1.13.244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-31
Starting with Software Version 1.13.244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33 Mode Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-35 4-35 4-36 4-37 4-38 4-38
Starting with Software Version 1.20.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40 System Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
iii
Table of Contents SECTION
(Continued)
TITLE
PAGE
Active TD Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Prior to Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43 Starting with Software Version 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44 5.
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 in Programmed Transition . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1 5-1 5-1 5-2 5-2 5-2 5-2 5-2 5-3 5-3 5-4 5-5 5-5 5-5 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-9 5-9
6.
AUTOMATIC TRANSFER SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1 6-1 6-1 6-2 6-3 6-3 6-3 6-3 6-3 6-6
iv
Table of Contents SECTION
(Continued)
TITLE
PAGE
Bypass, Isolate, and Remove the Automatic Transfer Switch . . . . . . . . . . . . . . . . To Bypass and Isolate the Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . To Remove the Automatic Transfer Switch (1200-Amp Bypass) . . . . . . . . . . To Remove the Automatic Transfer Switch (1600- to 3000-Amp Bypass) . . Install and Reconnect the Automatic Transfer Switch (When Finished) . . . . . . . . To install the Automatic Transfer Switch (1200-Amp Bypass) . . . . . . . . . . . . . To Install the Automatic Transfer Switch (1600- to 4000-Amp Bypass) . . . . To Reconnect the Automatic Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Actuator Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . Removing Actuator Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Actuator Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Assembly Removal and Replacement (1200 Amperes) . . . . . . . . . . . . . . Removing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Movable Contact Assembly Removal and Replacement (1600 − 2000 Amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Movable Contact Assembly Removal and Replacement (3000 Amperes) . . . . . . Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Switch Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and Replacing an Auxiliary Switch Assembly. . . . . . . . . . . . . . . . . Mis-Wired Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6 6-6 6-10 6-13 6-13 6-13 6-13 6-15 6-16 6-16 6-17 6-17 6-17 6-20 6-22 6-22 6-22 6-25 6-25 6-28 6-29 6-29 6-30
7.
BYPASS SWITCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Disconnect AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Reconnecting AC Power (When Finished) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Contact Assembly Removal and Replacement (1200 Amperes) . . . . . . . . . . . . . 7-1 Removing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Replacing the Contact Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Movable Contact Assembly Removable and Replacement (1600 − 2000 Amperes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Movable Contact Assembly Removal and Replacement (3000 Amperes) . . . . . . 7-9 Removing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9 Replacing the Contact Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
8.
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
8-1
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. DANGER This symbol warns of immediate hazards that will result in severe personal injury or death. WARNING
or death.
This symbol refers to a hazard or unsafe practice that can result in severe personal injury
This symbol refers to a hazard or unsafe practice that can result in personal injury or product or property damage. CAUTION
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. 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.
UTILITY-TO-GENSET OR GENSET-TO- GENSET APPLICATIONS If the cabinet must be opened for any reason: 1. Move the operation selector switch on the generator set to Stop. 2. Disconnect the battery charger. 3. Disconnect the starting batteries of the generator set or sets (remove the ground [−] lead first). 4. Remove AC power to the automatic transfer switch. If the instructions require otherwise, use extreme caution due to the danger of shock hazard.
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 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 TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE. BTPC-2
vi
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 1200−4000 amperes. This is a bypass transition (BT) transfer switch equipped with PowerCommand Control (PC) and it is capable of executing Open Transition with Sync Check, Programmed Transition, and Closed Transition transfer modes.
The BTPC transfer switch combines an automatic transfer switch, a manual bypass switch and a drawout isolation mechanism into one unit.
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. 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. A Closed Transition Transfer Mode executes a load transfer by momentarily paralleling both sources (a maximum of 100ms) before switching sources.
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. 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 suitable voltage and frequency range. SOURCE 1 (NORMAL)
Refer to the schematic and wiring diagram package that was shipped with the ATS for specific information about its configuration.
SOURCE 2 (EMERGENCY) ISOLATING CONTACTS
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. ES1968
BYPASS TRANSFER SWITCH LOAD
AUTOMATIC TRANSFER SWITCH
FIGURE 1-1. BTPC TRANSFER SWITCH (TYPICAL FUNCTION)
PowerCommand is a registered trademark of Onan Corporation. Onan and Cummins are registered trademarks of Cummins Inc.
1-1
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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 either along a rail or on rollers then engages and disengages the isolation contacts without disconnecting power or control cables.
preferred source. The control automatically transfers the load between the two utilities and detects alarm conditions. The exercise routine is not available with this configuration. The operator can select either source as the preferred source (see Figure 2-1). 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 2-1. PREFERRED SOURCE SUBMENU
UTILITY-TO-GENSET OPERATION
CONTROL LEVEL
In utility-to-genset applications, the transfer switch performs the following functions:
Only a Level 2 control is used with BTPC transfer switches.
1. Senses the interruption of the Source 1 power.
The control board level can be viewed using the digital display (see Figure 2-2). This menu is included in the About submenus (see Figure 4-29 or 4-30, depending upon software version).
2. Sends a start signal to the generator set (Source 2). 3. Transfers the load to the Source 2.
ATS Board Level
4. Senses the return of Source1.
2
5. Retransfers the load to Source 1. FIGURE 2-2. CONTROL LEVEL SUBMENU
6. Sends a stop signal to the generator set.
The following configuration types are available with BTPC transfer switches.
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.
• Utility-to-Genset • Utility-to-Utility The following transition types are available with BTPC transfer switches. • Open Transition with Sync-check
4. Retransfers the load to Source 1. The controller can control a two-utility configuration for prime power. One utility is designated the 1-2
• Programmed Transition • Closed Transition
REMOVING AND REPLACING ELECTRONIC CONTROL COMPONENTS
BTPCE 00000 Spec. A | | | | 1 2 3 4
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. WARNING
1. BTPC − Bypass Transition PowerCommand Control. 2. Ampere Rating: E = 1200 F = 1600 G = 2000 H = 3000 J = 4000
Disconnecting J10/P10 removes all power to the door. 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. 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.
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. Refer to page 1-4 for a list of feature/option codes.
The model number is made up of code segments that designate various features or options:
InPower is a trademark of Cummins, Inc.
3. Assigned spec number − issued for each specific combination of accessories, voltages, frequency and standards codes. 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 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. 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 1-763-574-8087. When contacting your distributor, always supply the complete Model Number and Serial Number as shown on the nameplate.
1-3
FEATURE DESCRIPTION
FEATURE OPTION
FEATURE DESCRIPTION
Poles: 3 Poles 4 Poles
Phase: A028 A029
1 Phase, 2-W or 3-W 3 Phase, 3-W or 4-W
Application: Utility to Genset Utility to Utility
Digital Bar Graph Meters 2A, 12/24VDC 10A, 12VDC 10A, 24VDC 15 Amp, 12 VDC 12 Amp, 24 VDC
A046 A044 A045
24 VDC Coil Emergency Position Normal Position Generator Start 12 VDC Coil Emergency Position Normal Position Generator Start
R038 R021 R022 R023 R024 R025 R035 R026 R027
Terminal Block − 30 Position Load Shed − From Emergency Terminal Block − Battery Chrg Alarms Cable Terminal Lugs
C024
Control Options: Front Panel Security Key Digital Display LONWORKS Network Com. Module Load Monitoring Relay Module
L101 L102 L103 L104 L201 L202 L203 L204
Miscellaneous:
Controls: Level 2 Switch Control
K001 K002 K003 KB59 KB60
Auxiliary Relays:
Voltage: 190 VAC 208 VAC 220 VAC 240 VAC 380 VAC 416 VAC 440 VAC 480 VAC 600 VAC
D009
Battery Charges:
Frequency: 60 Hertz 50 Hertz
A041 A042
Meters: A035 A036
Agency Approvals: UL Listing
FEATURE OPTION
M003 M007 N002 N008
Cabinet:
M017 M018 M020 M022 M023
Type 1 − General use, Indoor Type 3R − Outdoor use Type 4 − Indoor or Outdoor use Open Construction − No Enclosure Type 12 − Indoor, dust- and waterproof Type 4X − Stainless Steel
1-4
B001 B002 B003 B004 B010 B025
2. Component Description ous types are designated as general-purpose, indoor or outdoor cabinets.
This section describes the standard and optional control features as well as the control cabinet and bypass transfer switch.
CONTROL PANEL
CABINET
The panel features are divided into three groups:
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 and 12. The vari-
• Bar Graph Meter Panel (optional) • Switch Panel • Digital Display
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