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1. Attach a 12V battery or set the charger for 24V charging 1 7A 24V battery is con nected but the charger is 12V charging High Battery Voltage 442 HIGH BATT VOLT Cycle through the Setup menus to clear the fault and restart charging 2 Large load dump have caused momentary _ voltage rise Check level of input voltage Charger will not operate with voltage 10 or more below nominal AC input voltage is more than 10 below nominal rated voltage 2331 LOWAC Input Voltage Check level of input voltage Charger will not operate with voltage 10 or more above nominal AC input voltage is more than 10 above nominal rated voltage 2358 HIGH AC VOLT High Input Voltage Move the battery into a cooler location Charger will automatically begin charging again after the battery temperature lowers _ Battery s ambient temper ature is too high Battery Temp above 55 degrees C 2263 HIGH BATT TEMP For installations i that optional battery temperat re s nsor 2 Possible shorted cells Replace the battery within the battery is caus ing an excessive battery temperature increase Page 4 of 6 TABLE 1 TROUBLESHOOTING USING FAULT CODES CONT Some battery
2. 4 4 TESLPUSNDUNOMN vx OC On RE a rods 4 4 Override PUSHBUTTON v2 S e ED SO E ER RNC RE 4 4 set Exercise PUSBbUltol sibi adc em E S cl RR d 4 4 Test With or Without Load 4 5 Test With Load Sequence of 4 5 Test Without Load Sequence of Events 4 6 Table of Contents continued SECTION TITLE PAGE 4 7 TET ILS CT 4 7 Generator Sensor 24 Cg yai esce cw rai va hd wes sme 4 7 Phase Check Bees 4 7 2 Return to Programmed Transition amp 4 7 Generator Set Exerciser 9 4 8 Exercise With or Without Load Aene 4 8 Integrated Exerciser NC DUE RC PD Be 4 8 Optional External Exerciser 4 10 Exercise With or Without Load 22 2 4 10 Using the Menu Button oe eo Me 4 11 Using the Buttons 28 4 11 Using the ok EN reor 4 11 Setting the Clock with Summer Winter Time Daylight Savings Time 4 11 Setting Exercise Start a
3. OVERRIDE Off amp 2 50 To restart the exercise simultaneously press the and buttons for approximately one sec ond The original Home menu is redisplayed and Off is switched back to On 12 15 18 21 Auto 03 01 04 2 58 Selecting Permanent On Off Mode 645 380 24 The exercise clock has a permanent on off mode PERM OFF feature Off te 2 50 Selecting Permanent On Off Mode Without Active Exercise In the example shown below Off indicates that no 3 To return the clock to its original state simulta exercise is currently active neously press the and buttons for approxi mately one second The original Home menu is redisplayed 12 15 18 21 24 Auto ee d 04 Selecting Permanent Oh OffiMlode With an Active Exercise 2 50 In the example showngbelow indicates that an exercise is currently active 1 With the Home menu displayed simultaneous 212 FT ly press the and buttons for approximately Auto two seconds The Override menu is first dis d a 04 played and then the Perm On and the hand dot symbols are displayed on the screen In 2 50 s addition a continuous band of segments is dis played on the left side and top of the screen and Off is switched to On 1 WWith the Home menu displayed simultaneous ly press the and buttons for approximately 1 15 19 21
4. 3 8 Two Wire Starting 7 3 8 Transfer Switch 3 8 Contact Assemblies N 3 8 Linear Actuator Tort 3 8 Auxiliary Contacts 3 8 aaah adios EE E 3 9 Float Battery ChargerOption 3 9 Auxiliary 3 9 External Exercise Clock Option 3 10 Remote Input 3 10 4 4 Horde De ME Cd Md 4 1 Tine DeMUS 4 1 Time sBelay Engine Start TDES 4 1 Time D lay Engine Cooldown 4 1 Time Delay Normal to Emergency 4 1 Time Delay Emergency to Normal TDEN 4 1 Time Delay Programmed Transition 4 2 Time Delay Elevator TDEL Pre Transfer 4 2 Elevator Post Transfer Delay 4 2 Manual Operation 13533 3 i eu 4 3 Pushbutton Operation FUTT
5. two seconds The Override menu is first dis played and then the Perm Off and the hand ER dot symbols are displayed on the screen In ET addition On is switched to Off 2 50 12 15 18 21 24 1234567 RTS PEN 12 s 18 21 24 ges On amp 2 50 x 1234567 On 2 50 iPERM ON 12 15 18 21 24 ss oe PERM OFF 2 To switch to PermanenhOff mode press the Offre and buttonSfo approximately two seconds _ 9 50 Perm is displayed and is switched back to Off 4 23 2 To switch to Permanent On mode press the and buttons for approximately two seconds Perm On is displayed and Off is switched back to On In addition a continuous band of segments is displayed on the left side and top of the screen 12 15 18 21 24 iPERM On Be 3 To retum the clock to its original state simulta neously press the and buttons for approxi mately one second The original Home menu is redisplayed Adding A Security Code A 4 digit security code number can be entered to prevent unauthorized personnel from using the clock Once a security code has been set up the exercise clock is locked 90 seconds after the last keystroke It can only be operated again after the correct P IN code is entered Once a PIN code has beenactivated and the Reset button is pressed see Rese
6. up the time setting The battery is good foarsten years and doesn t needto be serviced The battery is attached to the time chip on the control board If no exercise period 5 Exercise LED is off see Figure 3 5 Setting the Integrated Exercise Period 1 Verify thathe Exercise LED is off and the Ex ternal Exereise function is disabled set to Off see Section 5 If the External Exercise func tion isenabled the integral exerciser is dis abled 2 To set the exercise start time for a repeat exer cise period press and hold the Set Exercise pushbutton for 5 seconds The Exercise LED flashes at a rate of twice per second for 5 sec onds and then stays on when the exercise peri od is set A delayed 20 minute exercise period will start in 12 hours At that time the Exercise LED flashes at a rate of once per second during the entire exercise period When the exercise period is over the Exercise LED quits flashing and remains on to signify that repeat exercise periods are enabled 3 To start an immediate exercise period and have it repeat momentarily press the Set Exer cise pushbutton a second time within ten sec onds of starting the delayed exercise period Momentarily pressing and releasing the Set Exercise pushbutton a second time starts an immediate 20 minute exercise period instead of waiting for 12 hours The Exercise LED flashes at a rate of once per second during the entire exercise period When th
7. 5 REMOTE TEST e 6 TRANSFER INHIBIT 7 RETRANSFER INHIBIT 3 COMMON em FIGURE 3 13 CONNECTIONS FOR REMOTE OVERRIDE INPUT 4 Operation TIME DELAYS The transfer switch control uses various time delays to break from one power source and reconnect to the other source The control panel can be used to adjust these time delays see Section 5 In the following descriptions of time delays itis im portant to remember that e When the tranfer switch is connected to Nor mal it is connected to the utility power source e When the transfer switch is connected to Emergency it is connected to the Genset power source e When the transfer switch is in the Neutral position it is not connected to either power source Time Delay Engine Start TDES This time delay prevents the generator from starting during brief utility power interruptions This timer starts the instant the utility fails as detected by the Undervoltage Sensor When the control senses a utility failure the control starts the Time Delay Engine Start TDES timer This time delay is configurable for 0 disabled 0 5 1 2 3 4 6 or 10 seconds default seconds If utility power returns while thal DES timer is ac tive the timer is reset When the timer expires the control de energizes the start relay closing the start contact signalling the generator to start The timer is not reset until utility power returns If the
8. VALUE VALUE Default in FOR TDEN CODE bold italics O O OMinutes Disabled 0 1 Minutes b There be an active retransfer inhibit If a retransfer inhibit is enabled the load transfer will not take place until the Override pushbutton on the control panel is pressed the retransfer inhibit input is disabled or the genset fails There may an active TDEL Wait until the time delay has expired The TDEL can be set for up to 300 seconds FUNCTION CODE VALUE VALUE Default in FOR TDEL CODE bold italics ef ism Oe Of Sew Oe e Sens le o o 5Seods e 30 Seconds 120 Seconds e 300 Seconds d A phase check may be enabled When the phase check function is enabled the utility does not assume the load until both sources are within acceptable limits of the phase check sensor If the Utility Power Available LED is not lit a Check the control setting to verify that the utility undervoltage dropout point is set low er than the pickup set point 2 If the problem persists call your dealer or dis tributor Generator Set Continues to Run After Retransfer of Load to Normal Power 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 When the cabinet door is open use ex treme caution to avoid touching electrical con tacts with body tools
9. printed _ 962 0131 6 2004 Supplement 962 1037 Date 3 2005 Insert with Titles BTPC OHPC CHRC and OTEC Transfer Switch Operator s Installation and Service Manuals Numbers 962 0126Aj d t d 10 2002 962 0128A dated 10 2002 962 0130B dated 10 2003 962 0131 dated 6 2004 962 0516 dated 10 2002 962 0517A dated 10 2002 962 951 8 dated 10 2002 962 0519 dated 10 2002 962 0520B dated 7 2004 962 0521 dated 8 2004 962 06124 dated 10 2002 962 0614A dated 10 2002 962 0616B dated 10 2003 962 0617 dated 6 2004 PURPOSE This supplement updates the OTPC BTPG OHPC CHPC and OTEC Transfer Switch Operator s Installation and Service Manuals to includewnformation on the 15 12 amp battery charger option which replaces the 10 amp battery chargekoption currently described in these manuals SUPPLEMENT USE Much of the information currently included in the manuals applies only to the 2 amp and or 10 amp battery chargers that were originally available on the transfer switches If your installation includes the new 15 12 amp battery charger refer only to the information included in this supplement Exist ing general information concerning battery charger malfunction fault code 597 OTPC and BTPC manuals or the charger error event OHPC CHPC manauls also applies to 15 12 amp battery chargers Write Refer to Supplement on the pages ofthe manuals listed abo
10. Equalizing Red On solihindicates a fault condition The fault number is shown on the digital display FIGURE 1 15 12 AMP POWERCOMMAND BATTERY CHARGERS Page 2 of 6 LED STATUS INDICATOR DIGITAL DISPLAY PowerCommand _ RESET BUTTON FIGURE 2 CONTROL PANEL Optional Battery Temperature Sensor A connector for an optional battery temperature sen sor is located on the front of the battery charger see Figure 1 When used to monitor battery tempera ture the optional battery temperature sensor is con nected from the battery charger to the positive tenmi nal of the battery A fault message fault code 2263 is displayed if the battery temperature is too high reaches 131 degrees F 55 degrees C BATTERY CHARGER CONFIGURATION The RESET button on the control panel see Figure 2 is used to configure the battery charger More in formation on Setup menus is included in the Battery Charger Operator s Manual Battery Voltage and Type The battery charger 4must be Correctly configured using the Setup forthe correct battery volt age and type before jt is Connected to the battery The battery voltage can set for 12 or 24 VDC de fault 12 VDC type can be set for Lead Acid Gel Ni Cad or AGM batteries default Lead Acid NOTE A factory installed battery charger is set up for the proper DC battery voltage requested on the production order with the Le
11. The Menu button can also be used to abort adjusting pa rameters and return to the Home menu Using the Buttons Pressing the or button is used to e Increase or decrease a parameter an adjust able menu e Select the next or previous menu Simultaneously pressing the amp and buttons is used to select special functions e Initiate an exercise see page 4 22 Override an activetexereise see page 4 22 e Select permanenton off mode see page 4 23 Using the ok Button The ok button is used to confirm the menu selection or program adjustments you have made Upon pressing the ok button the next available menu is displayed and if any program adjustments were made the changes are saved 4 11 Setting the Clock with Summer Winter Time Daylight Savings Time The clock is programmed with the correct date and central USA standard time and with the comectday light savings time settings If it is necessary to change these settings the following describes how to adjust the time and date and how to clock to automatically switch to summer winter time day light savings time 1 Press the Menu button on the exercise clock dhe Program menu is displayed FLASHES 12 151 18 21 Auto Prog 9 PROGRAM 2 Press the button The Date Time menu is dis played FLASHES Auto Prog 9 3 11 07 FLASHES 4 Press the or but
12. The contacts are rated at 2 amps 30 VDC This feature can be used by wiring a fault indicator to the fault alarm output connector located on the front of the battery charger see Figure 1 A 2 pin plug connec tor 323 1678 02 is shipped with the 15 12 amp transfer switch battery charger Page 3 of 6 TABLE 1 TROUBLESHOOTING USING FAULT CODES Some battery charger service procedures present hazards that can result in se vere personal injury or death Only trained and experienced personnel may perform service wARNING gnition of explosive battery gasses can cause severe personal Do not smoke or causean spark arc or while servicing batteries 379 OVER CURR Output Overload Output current is excessive Cycleathrowgh the Setup Charger control may be menus clear the failing fault Ifthe fault returns the charger control may have failed 1 No battery connected Connect the battery m 2 Output breaker is in the Verify the output breaker is in Off down position up position 3 A 12V battery is Attach a 24V battery orset nected but the charger is the charger for 12V charging set for 24V Charging 4 Battery longer Replace the battery maintain charge 5 The wire between the Check the wire charger and the battery is loose ot broken 441 LOW VOLT Low Battery Voltage
13. anaes ia b Push the lower manual operator handle down Retransfer from the genset Emergency to the utility Normal a Pull the lower manual operator handle up b Push the upper manual operator handle up NOTE Remember that the transfer switch transfers the load to the active power source If Hoth sources available eit transfers the load to the utility Automatic transfer switch op eration results in rapid movement of the manual operator handles and presents a hazard of severe personal injury Keep hands clear of handles when switching back to automatic operation 5 To return to automatic operation restore power to the control by reconnecting the J1 connector 6 Close the cabinet door TRANSFER SWITCH HANDLES LOWER HANDLE FIGURE 4 1 MANUAL OPERATION HANDLES PUSHBUTTON OPERATION The following describes operation of the three pushbuttons located on the control panel Test Pushbutton The Test pushbutton is used to e Start a genset test The Exercise LED flashes if the Test pushbutton is pressed and held for two seconds e Terminate a genset test The Exercise LED goes out if the Test pushbutton is momentari ly pressed More information on testing is included on the fol lowing pages Override Pushbutton The Override pushbutton is used to e Terminate the following system time delays Time Delay Engine Start TDES Time Delay Nor
14. ercise period overlaps the time frame of the first ex ercise period in the current day two start times are displayed followed by two stop times 1 From the Home menu press the Menu button The Program menu is displayed FLASHES 12 15 18 21 24 s P Auto Prog PROGRAM 2 Press the ok button The New Program menu is displayed 2 as 18 ik ae FLASHES _NEW PROG 3 Press the button once The Check menu is displayed N 74 A 24 FLASHES 4 Press the ok button The Monday menu is dis played 12 15 18 21 gt FLASHES NOTE If no exercise periods set up the message Empty issdisplayed To re turn to the menu press the ok button 142 8 15 18 21 Prog EMPTY 5 Use the amp or buttons to select the day of the Week you wish to check Press the ok button Thexstarting time for the first exercise for the se lected day is displayed 12 15 18 21 Prog FLASHES NOTE If a day does not have any set exer cise periods the screen below is dis played 12 15 18 21 FLASHES 6 Press the ok button The ending time for the first exercise for the selected day is displayed a 15 18 21 24 g 3 a Prog FLASH ES NEXT Off _ 12 00 7 Press the ok button The next exercise start time is displayed If the next start time is not on the day selected in step 5 the day of the week is in
15. for signs Of wear or deterioration Check all control wiring and power cables for loose connections Tighten as indicated in step 4 Check the cabinet interior for loose hardware Tighten as indicated in step 4 4 27 4 Perform Routine Maintenance A Tighten buswork control wiring power cables and system hardware as necessary Hardware torque values are given in section 4 of the Service Manual 962 0521 Retorque all cable lug con nections Lug torque requirements are listed in section 1 of the Service manual 5 Connect AC Power and Check Operation A Connect the set starting battery negative lead last Connect the utility AC power source enable the genset power source If applicable connect power to the battery charger B Verify proper operation of the battery charger C Test system operation as described in this section Close and lock the cabinet door 4 28 5 Control Panel Configuration The control panel can be used to configure ATS functions When in Configuration Mode the value code for the various control functions can be modi fied The control panel has a series of eight LEDs that display codes that indicate various control functions that can be configured The first five LEDs display the function code and the last three LEDs display the value code for the displayed function see Fig ure 5 1 A listing of the control functions including the function and value codes is included in
16. hold a charge or been damaged excessively due to extremely deepsdiseharge HIGH BATT VOLT 1 By disconnecting the charger harness plug 2 By cycling completely through the Setup menus Move the charger to a cooler location The charger will automatically 5egin charging again after the internal temperature lowers Verify that the charger s air inlets on the side of the Charger are not blocked and nothing is interfering with fan rotation Replace the battery and cycle through the Setup menus to clear the fault and 9115 BATT FAIL can only be cleared ratings are shown on the charger faceplate If the fuse is OK call your dealer or distributor Battery Loses Charge Battery charger float voltage could be too low if equipped with battery charger Call your dealer or distributor SERVICE MANUALS 962 0517A 962 0518A 962 0519 962 0520 AND 962 0521 The following information describes the battery charger feature codes that are now available with LT and LC transfer switches FEATURE FEATURE DESCRIPTION OPTION Battery Charges 2 Amp 12 24VDC 15 Amp 12VDC 12 Amp 24VDC K001 KB59 KB60 Page 5 of 6 roubleshootin placement fuses are listed in the battery charger Op Troubleshooting tf listed in the batt h mE erator s Manual Most troubleshooting issues result in fault codes that are displayed the bat
17. jewelry clothes hair etc 1 The engine cooldown time delay may not have expired The TDEC can be set for up to 30 min utes FUNCTION CODE VALUE VALUE Default in FOR TDEC CODE bold italics Que 00 0 Minutes Disabled 0 1 Minutes e e e somnus 7 T 2 Stop the generator set with its Start Stop switch Call your dealer or distributor System Does Not Test With Load AC power withinfhe cabinet and the rear side of the cabinet door presents a shock hazard that can cause seVere personal injury or death When the cabinet door is open use ex treme caution to avoid touching electrical con tacts with body fools jewelry clothes hair etc 1 Check the control setting to verify that the Test With Without Load function has been set to With Load 2 If the control has been set to Test With Load transfer time delay may not have ex pired The TDNE can be set for up to 300 Seconds If you do not wish to wait until the 6 5 time delay expires press the Override pushbutton VALUE CODE FUNCTION CODE FOR TDNE VALUE D fault n bold italics Seconds Disabled 1 Second 2 Seconds Seconds 30 Seconds 120 Seconds e 6 300 Seconds b There active transfer inhibit If a transfer inhibitis enabled the load transfer will not take place until the Override push control panel is pressed or the transfer inhibit input i
18. 18 21 24 a a FLASHES 3 Press the button once The Check menu is displayed 12 15 18 21 24 FLASHES 4 Press the ok b ttonZThe Monday menu is dis played 4 19 12 15 18 21 24 FLASHES 5 If necessary use the or b ttons to select the day of the week that includes the exercise end ing time you wish to delete 12 IS 15 21 224 LI P FLASHES Prog FRIDAY FLASHES _7 Press the or buttons until Clear is dis _ played 12 18 21 24 a FLASHES 8 Press the ok button The New Program menu is redisplayed Individual or all exercise periods can also be cleared For more information see Erasing Clear ing A Programmed Exercise Period and Erasing Clearing All Exercise Periods below Erasing Clearing A Programmed Exercise Period 1 From the Home menu press the Menu button The Program menu is displayed FLASHES Auto Prog PROGRAM 2 Press the ok button The New Program menu is displayed 15 18 FLASHES Prog NEW PROG 3 Press the or button until the Clear menu is displayed 12 15 18 21 FLASHES Prog CLEAR 4 Press the played FLASHES 4 20 5 Press the ok button The first exercise start time of the week is displayed To select adiffer ent exercise start time press the or buttons until the desired time is displayed 12 15 18 21
19. 30 FIGURE 3 12 EXTERNAL EXERCISE CLOCK The optional external exercise clock includes a real time clock that keeps track of the time and date The clock can be set for automatic changeover for sum mer winter Daylight Savings Standard time The exercise clock can be used with 12 or 24 VDC op eration Up to 28 programs are available to set exercise start and stop times One program is required to start an exercise period and a second one 15 required to stop an exercise period P5 123456789 The exercise clock has a built in test feature that can be used to initiate an exercise that hasn t been programmed or cancel a programmed exercise process Information on setting the clock is included in Sec tion 4 NOTE The clock includes a nionsfeplaceable lithi um battery with a of at least ten years If the clock battery is weak during a power failure the clock will need to be re placed Remote Override The transfer switch may be wired with a remote Override Switch that functions the same as the con trol panel Override pushbutton A remote override input is set up by connecting a dry voltage free contact between P4 2 on the back of the control panel and TB2 8 see Figure 3 13 Closing the contact enables the feature and open contact disables it a NER ols 1 GND IS 2 2 B 4 RMT
20. BATTERY CHARGER GROUND POWER eis LUGS TRANSFORMER cies 600 VOLT UNITS ONLY FIGURE 3 4 INTERIOR COMPONENTS 300 600 AMP SWITCH TYPE 3R AND 12 CABINET 800 1000 AMP SIMILAR CONTROL PANEL Control Function LEDs The control panel see Figure 3 5 includes eight SNOWS paneron cabinet LEDs that display codes that indicate various ane trol functions that can be configured Th amp firstfive groupe LEDs display the function code and the last three LEDs display the value code for the displayed func e Control Function LEDs tion For information on configuring thesefunctions see Section 5 e ATS Status LEDs With the exception of the firsQLEDs Test normally these LEDs are off and libwhen in Configu ration Mode The Test LED i also used to notify the user of test periods TEST CONTROL ACTIVITY LED FUNCTION LEDs UTILITY POWER GENSET AVAILABLE POWER LED AVAILABLE LED TEST GENSET PUSHBUTTON POWER CONNECTED LED SET EXERCISE ACTIVE UTILITY POWER OVERRIDE PUSHBUTTON EXERCISE LED CONNECTED LED FIGURE 3 5 CABINET DOOR 3 5 ATS Status LEDs The control panel includes six LEDs that provide Automatic Transfer Switch ATS status informa tion Utility Power Available This green LED is lit when the utility power source has acceptable output voltage Genset Power Available This amber LED is lit when
21. FLASHES Prog 6 Press the ok button New Program menu is redisplayed 25 A FLASHES 7 Repeat steps 3 thru 6 to erase the stop time for the exercise period erased above 8 If necessary repeat steps 3 thru 7 for any addi tional exercise periods that need to be erased 9 When the New Program menu is redisplayed press the or buttons until the word END is displayed 12 15 18 21 24 2 15 18 21 2 a FLASHES END 10 Press the ok button to retum to the Home menu Erasing Clearing All Programmed Exercise Periods 1 From the Home menu press the Menu button The Program menu is displayed FLASHES Auto Prog PROGRAM 2 Press the ok button The New Program menu is displayed FLASHES 3 Press the or buttons until the Clear men is displayed 12 15 18 21 FLASHES Prog CLEAR 4 21 4 To clear all set exercise periods press the Or buttons until is displayed Press the ok button 12 15 18 21 um FLASHES 5 The word Confirm 45 displayed To continue clearing all exercise programs press the ok button To abort clearing all exercise programs press the or buttons 12 18 21 FLASHES Prog QONFIRM 6 The new program menu is redisplayed Press the or buttons until the word END is dis played 12 15 18 21 Prog FLASHES END 7 Press the ok button to return to the Home me
22. LEDs 4 When configuration is completed return the selector switch back to the Automatic Mode position 123456789 P5 SWITCH IN CONFIGURATION MODE FIGURE 5 2 NORMAL CONFIGURATION MODE SELECTOR SWITCH 5 4 6 Troubleshooting The following procedures describe preliminary trou bleshooting checks If the trouble persists call your dealer or distributor CONTROL PANEL INDICATORS The control panel contains six LED indicators that provide some information about the current control status and may be helpful in troubleshooting the transfer switch see Figure 6 1 Descriptions of these indicators are included in Table 6 1 TROUBLESHOOTING Some ATS service procedures present hazards that can result in severe per sonal injury or death Only trained and experi enced service personnel with knowledge of electricity and machinery hazards should per form service See Safety Precautions ACTIVE TEST LED UTILITY POWER AVAILABLE LED UTILITY POWER CONNECTED LED Diagnosis of problems involves observing syStem operation If you cannot determine the problem contact Cummins Onan Service 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 Whenever the c binet door is open use extreme caution to avoidgstouching electrical contacts with body tools jewelry clothes hair etc Several of thesstepsulisted on the follow
23. Override pushbutton is pressed or the Override input is grounded while the T DES timer is active the TDES timer immediately expires Time Delay Engine Cooldown TDEC This time delay allows the generator to cool down under no load conditions before the control turns it off The Time Delay Engine Cooldown TDEC starts timingwhenthe load is retransferred to utility power This time delay is configurable for disabled 0 1 4 1 5 10 15 20 25 or 30 minutes default 4 0 min utes When the TDES expires the stop signal is sent to the generator and the timer is r set Pressing the Override pushbutton or grounding the Override in put has no effect on this timetdelay Time Delay Normal to Emergency TDNE This time delay allows theygenerator to stabilize be fore the load is applied While connected to Normal this time delay starts after utility power fails and the generator becomes available the amber Genset Power Available LED is lit This tim delay also starts after the generator becomes available when a with load Test or Exer cis period is activated The time delay is configurable for 0 disabled 1 2 3 5 30120 or 300 seconds default 5 seconds If the generator fails any time during a TDNE the control resets the timer and restarts it once the gen erator is again available If the Override pushbutton is pressed or the Over ride input is grounded while the TDNE timer is ac tiv
24. Table 5 1 Additional information on these functions is in cluded in Section 4 With the exception of the Test LED the function and value LEDs are not lit during automatic operation Automatic Mode ACCESSING THE FRONT PANEL CONFIGURATION EDITOR AC power within the cabinet and the rear side of the cabinet door presents a shock FUNCTION INDICATOR LEDS hazard that can cause severe personal Injury or death Use extreme caution to avoid touching electrical contacts whenever the cabinet door is open Battery power DC power must be available to con figure the control panel function SAC power may be present but doesn t have to be present to configure the control panel To check for DC power open the tranfer switch door and place the ATS in the Normal or Emergency position The Utility Power Con nected or Genset Power Connected LED should light _ ConfigurationMode is selected by operation of a small slide Switch located on the back of the control panel Ihe switch is located near the bottom edge of the see Figure 5 2 The switch is partially hid den to prevent accidental operation NOTE The Configuration Mode can be entered at any time but once it is selected all automat ic operation is suspended VALUE INDICATOR LEDS FIGURE 5 1 CONTROL PANEL TABLE 5 1 ADJUSTABLE TRANSFER SWITCH FUNCTIONS FUNCTION FUNCTION CODE VALUE CODE VALUE Default in bold italics Not Available
25. becomes active the Exerciser LED flashes at a rate of once per sec ond 2 The control signals the generator to start When the generator output is acceptable the control transfersthe load to the generator fol lowing the configuration set points 4 After thegexercise period has ended the control retransfers the load back to the utility following the configur d set points 5 Onee the load is connected to utility power the control runs the genset unload for the duration of the cooldown timer TDEC 6 After the TDEC timer expires the control sig nals the genset to stop 7 Unless the repeat exercise periods have been canceled the Exercise LED quits flashing and remains on to signify that repeat exercise peri ods are set If the exerciser is not set up to re peat exercises the Exercise LED goes out OPTIONAL EXTERNAL EXERCISER The optional external exercise clock is a 7 day 24 hour clock that when installed can store and execute several start stop programs per day and re peat exercise periods every week It can be grammed to run exercise periods at different times on different days Unlike the integrated exerciser the external exercise can schedule an exercise pe riod for something other than 20 minutes If the External Exercise function is enabled set to On then the integrated exerciser is disabled NOTE After a period of inactivity the clock enters sleep mode and turns off the disp
26. charger has anvammeter to indicate charging current and fus to protect the battery charger circuit The 10 ampere batteryechargers have three fuses two on the AC input andene on the DC output three fault display LEDS and an ammeter for indica tion of charging current On the 10 ampere chargers three sets of Form C alarm contacts c rresponding to the three fault LEDs are also available Using an optional alarm contact harness these contacts can be wired by the install rto activate other audible or visual alarms Under normal operating conditions the Low Bat and AC Fail relays are energized and the High Bat relay is de energized In response to a Low Bat or AC Fail condition the appropriate normally ener gized relay Low Bat or AC Fail drops out In re sponse to a High Bat condition the normally de en ergized High Bat relay is energized Auxiliary Relay Option Optional 12 and 24 VDC auxiliary relays provide contacts for energizing external alarms remote in dicators and control equipment such as louver mo tors and water pumps MOUNTING PANEL LOCATED ON THE UPPER LEFT SIDE INSIDE THE TRANSFER XX SWITCH CABINET ee A 7 E 2 AUXILIARY RELAYS SSSSSSSSSSSSS NS S ANS 777772722000 CUM FIGURE 3 11 CONTROL WIRING CONNECTIONS External Exercise Clock Option nim Auto 03 01 04 3 Off 11
27. e TDES Time Delay Engine Start Pg Ref 1 Seconds Disabled 0 5 Second 1 Second 2 Seconds 4Seconds 6 Seconds 10 Seconds 0 Seconds Disabled 1 Second 2 Seconds Seconds BA A TDNE Time Delay Normal to Emergency 30 Seconds 120 Seconds 300 Seconds 0 Minutes Disabled 0 1 Minutes For Testing 5 Minutes BA TDEN Time Delay Emergenc to Normal e e O O 15 Minutes 20 Minutes 25 Minutes 30 Minutes 0 Minutes Disab 0 1 Minutes For o 4 1 TDEC Time Delay Engine Cooldown 5 Minutes 10 Minutes 15 Minutes 20 Minutes ances 25 Minutes 30 Minutes 4 2 TDPT Time Delay Program Transition 0 5 Second 1 Second O 2 Seconds 3 Seconds 4 Seconds 6 Seconds i 10 Seconds TABLE 5 1 ADJUSTABLE TRANSFER SWITCH FUNCTIONS CONT FUNCTION FUNCTION CODE VALUE CODE TDEL he o o sn o e e o 7 e 300 Seeonds Without Load With Load 55 4 Without Load With Load us EE x gt 7 gt gt SPP PERS a PT SSMS ERS i NY a Utility Undervoltage Pickup Utility Undervoltage Dropout Q Phase Check On Off OS S N ON Return to Programmed Tran
28. flashing the exercise period has not yet started Inte grated exercisers do not display exercise start and stop times If the optional external exerciser is enabled check the exercise clock to see when an exercise is scheduled Start the generator set using its start stop con trols If it does not crank check the starting bat teries If it cranks but does not start check the fuel supply Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any spark or flame while servicing batteries Ignition of fuel can cause se vere personal injury or death by fire or ex plosion Do not permit any flame cigarette spark pilot light arcing switch or equip ment or other possible source of ignition near the fuel system If the problem persists call your dealer or dis tributor After a Power Failure the Generator Set Starts But Does Not Assume the Load 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 When the cabinet door is open use ex treme caution to avoid touching electrical con tacts with body tools jewelry clothes hair etc 1 Check to see if the Genset Power Available LED on the control panel is lit If the Genset Power Available LED is not lit Check the output voltage of the power source by observing the voltmeter on the generator set a Check the control setting to v
29. test period Th control can be configured to test tion see Section 4 The Test pushbutton is also use n the Configura tion Mode to step through the stion codes see Section 5 minate or bypass some time c ays to stop the Power Connected LEDs from fla ing as a result of a failure to connect to or discon sct from a power source and to cancel an active period For more information see Section 4 The Override pushbutton is also 2224 in the Config uration Mode to step through the value codes see Section 5 Set Exercise The Set Exercise pushbutton is used to set or cancel repeat exercise periods using the integrated exerciser For more information see Integrated Exercises on page 4 8 ELECTRONIC CONTROL SYSTEM This section describes the standard and optional components of the electronic control system Improper calibration or adjustment of electronic control modules can cause death severe personal injury and equipment or prop erty damage Calibration and adjustment of these components must be performed by tech nically qualified personnel only Installation of these components and calibration and adjustment procedures are described in the Installation Manual which is shipped with the trans fer switch and in the Service Manual which is avail able through your distributor AWARNING Accidental actuation of the linear motor could cause severe personal injury AC power
30. the genset power source has acceptable out put voltage and frequency Both power source LEDs can be lit simultaneously Utility Power Connected This green LED is lit when utility power is supplying power to the load This LED flashes once per second if there is a fail ure to connect to or disconnect from utility power when commanded The control makes five at tempts there is ten seconds between each at tempt to conne t ts or disconnect from utility power before it flashes the failure Genset Power Cennected This amber LED is lit when the genset is supplying power to the load This LED flashes ence per second if there ista fail ure to connect to disconnect from the genset when The control makes five at tempts there is ten seconds between each at tempt to connect to or disconnect from the genset before it flashes the failure Test This amber LED is lit when there is an active test period This LED flashes second when the Test pushbutton is pressed to set or can cel a test period Exercise This amber LED lights when repeat ex ercise periods have been set This LED flashes twice per second when the Set Exercise pushbutton is pressed to set or cancel an exercise This LED flashes once per second during an active exercise period Membrane Pushbuttons The control panel includes three membrane push buttons Test The Test pushbutton is used to set or cancel a
31. 1 FLASHES Pro NEW PROG 14 Press the ok button to enter a time the exercise is to end The numberof available program mable time periods 4s temporarily displayed Please note thatthe number of available pro grammable time periods has now decreased by one 4 16 12 15 18 21 NUMBER OF AVAILABLE PROGRAMMABLE TIME PERIODS Prog FREE 27 15 The Ending Time Time Off fmenu is displayed Press the ok button 12 15 18 24 Pro x g TIME OEF Off FLASHES 16 Repeat steps 5 thru 13 to set the stop time for yourexercise 17 When the New Program menu is redisplayed press the or buttons until End is displayed 12 15 18 21 24 s a P FLASHES D 18 Press the ok button to return to the Home menu NOTE If there are any exercises scheduled for the current day those time periods are indicated on the screen SCHEDULED EXERCISES Checking the Programs The Check Program menus can be use to review all set exercise start stop times and if necessary de lete them NOTE If the Menu button is pressed while view ing start stop programs the Program Check function is aborted and the Home menu is redisplayed Reviewing Exercise Start Stop Times All exercise start and stop exercise parameters can be viewed from the Program Check menu Normal ly the starting time is followed by the ending time for a programmed exercise However if a second ex
32. Exercises will not repeat if this feature is set to Off Battery Charger Fails To Charge If Equipped Check the battery charger fuse s Replace if nec essary with fuses of the correct rating Fuse am pere ratings are shown on the charger faceplate AWARNING Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any spark or flame while servicing bat teries If the fuse is OK call your dealer or distributor Battery Loses Water The battery charger float voltage could be too high if equipped with battery charger Adjust the float setting optional 10 amp charger only If the prob lem continues call your dealer or distributor Battery Loses Charge Battery charger float voltage could be too low if equipped with battery charger Adjust the float set ting optional 10 amp charger only If the problem continues call your dealer or distributor 0 International Use 8 7229
33. Post Transfer Delay below Elevator Post Transfer Delay The Elevator Post Transfer Delay feature keeps the elevator output active for the same TDEL time peri od after the transfer switch transfers Instead of de activating the elevator output when the pre transfer time delay expires the control keeps the output ac tive and starts the TDEL timer again after it senses that the transfer switch has transferred When the TDEL timer expires the second time the control de activates the elevator output The Elevator Post Transfer Delay is configurable to be enabled On or disabled Off default 2 Off MANUAL OPERATION The transfer switch has operator handles for manu ally transferring the load see Figure 4 1 Manual operation must be performed by qualified personnel under NO LOAD CONDITIONS ONLY Use the fol lowing procedure AWARNING Manual operation of the transfer switch under load presents a shock hazard that can cause severe personal injury or death Do not attempt to operate the switch manually when it is under load Follow the Safety Re lated Work Practices listed in NFPA 70E 1 Verify that the transfer switch is not under load 2 Open the cabinet door of the automatic transfer switch 3 Remove power to the control by disconnecting the J1 connector see Figures 3 1 thru 3 4 4 Transfer from the utility Normal to the genset Emergency a Pull the upper manual operator handle down
34. RANSFER INHIBIT RETRANSFER INHIBIT COMMON FIGURE 3 8 TB2 CONNECTIONS FOR REMOTE TEST TRANSFER 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 gen erator set AMopen switch stops the generator NOTE Three wire starting is not available on OTEC transfer switches TRANSFER SWITCH The transfer switch see Figures 3 1 thru 3 4 opens and closes the contacts that transfer the load be tween the power sources The switch is mechani cally interlocked to prevent simultaneous closing to both power sources The main parts of the switch discussed here are the contact assemblies linear actuator and auxiliary contacts Contact Assemblies The automatic transfer Switch has either three or four poles Three pole transfer switches are pro vided with a neutrakbar Phe contact assemblies make and break the curreht flow When closed to ei ther power source the contacts are mechanically held A mechanical interlock prevents them from closing to b th power sources at the same time Linear Actuator The Jinear actuator is a linear induction motor that moves the contact assemblies between the con tacts of both power sources Linear actuator opera tions initiated automa
35. TH SEVERE PERSONAL INJURY AND OR EQUIPMENT DAMAGE SER VICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND ORMECHANICAL SERVICE OTEC 1 1 Introduction OPERATOR S MANUAL This manual covers models produced under the Cummins Onan and Cummins Power Genera tion brand names This manual provides information necessary for op eration of an OTEC transfer switch This is an open transition transfer switch that includes an automatic transfer switch ATS control With an open transi tion switch there is never a time when both sources are supplying power to the load Programmed transition switches briefly pause in the neutral position of the transfer switch between switched positions so that transient currents from the load can diminish before the load is switched to the other source o TRANSFER SWITCH APPLICATION Transfer switches are an essential part of a build ing s standby or emergency power system The util ity line normal power is backed up by a generat r set emergency power The transfer switch auto matically 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 the utility as illustrated If utility power is interrupted the load is transferred to the generator set genset Whenoutility power re turns the load is retransferred to the Utility The
36. ad 6 4 After Power Returns the Transfer Switch Does Not Return To Normal Position 6 4 Generator Set Continues to Run After Retransfer of Load to Normal Power 6 5 System Does Not Test With Load 6 5 system Does Not Exercise With Load 6 5 External Exercise Clock Does Not Start An Exercise 6 6 External Exerciser Does Not Repeat an Exercise 6 6 Battery Charger Fails To Charge Equipped 6 6 Battery Loses 6 6 Batlery Loses ONJE meteo 6 6 Safety Precautions This manual includes the following symbols to indi cate potentially dangerous conditions Read the manual carefully and know when these conditions exist Then take the necessary steps to protect per sonnel and the equipment This symbol warns of immediate hazards that will result severe personal injury or death This symbol refers to a hazard or unsafe practice that can result in severe per sonal injury or death This symbol refers to a hazard or unsafe practice that can result in personal inju ry or product or property damage ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH High voltage in transfer switch components pres ents serious shock hazards that can result in severe personal injury or death Read and follow these suggestions Keep the tr
37. ad Acid battery type selected as the default Battery Equalization Battery equalization is available for lead acid batter ies that are completely charged using the Equalize Battery screen the Setup menus When battery equalization is in process LED status indicator turns amber TROUBLESHOOTING AND FAULTS The 15 12 amp batt ny charger includes one set of Form B alarm contaets Corresponding to the status LED on the panel When red this LED indi cates a fault condition The control panel also dis plays the fault codes listed in Table 1 When fault occurs the red fault LED lights and a brief description of the fault and the numeric fault code iStdisplayed on the digital display see Fig ure 2 To Correct the fault find the fault code num Table 1 and take the suggested corrective ac tions If the problem persists call an authorized Cummins Power Generation distributor for help Clearing Faults Most displayed faults are cleared by removing the fault However faults 379 OVER CURR 442 HIGH BATT VOLT and 9115 FAIL can only be cleared by cycling completely through the Setup menus or by powering down the charger after the fault is corrected More information on Setup me nus is included in the Battery Charger Operator s Manual Fault Alarm Output Connector The battery charger includes a fault output relay that is activated contacts close when faults occur
38. al position for an adjustable period of time whenever there is a transfer from one source to another The intentional delay allows the residual voltage of an inductive load to sufficiently decay be fore connecting it to another power source This delay prevents potentially damaging voltage and current transients in the customer s power system If TDPT is set to zero then the transfer switch trans fers from one source to the other with no neutral position delay The control activates a Program Transition Time Delay TDPT whenever the transfer switch has dis connected from one source and is in the Neutral position The time delay is configurable for O dis abled 0 5 1 2 3 4 6 or 10 seconds default 0 seconds The control also detects if the transfer switch has disconnected from the first source fore connecting it to the second source If there is a power source failure while the TDPT is active the control only transfers to the remaining active power source The control doesnot termi nate the timer if either source fails while the transfer switch is in the Neutral position Time Delay Elevator TDEL Pre Transfer Primarily used in elevator applications this delay sets a time to wait for an elevator pre transfer sig nal This signal allows the elevator to come to a complete stop before the switch transfers The elevator pre transfer signal and associated time delay is used to signal an elevator con
39. ansfer switch cabinet closed and locked Make sure only authorized personnel have th cabi net 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 electrician or authorized service representative UTILITY TO GENSET APPLICATIONS If the cabinet must be opened for any reason 1 Move the operation selectorswitch on the gen erator set to Stop 2 Disconnect the battery charger 3 Disconnect the starting batteries of the genera tor set or sets remove th ground lead first 4 Remove AC power to the automatic transfer switch th instructions require otherwise use extreme caution due to the danger of shock hazard GENERAL PRECAUTIONS Place rubber insulative mats on dry wood platforms over metator concrete floors when working on any electricakequipment 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 trans fer 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 un safe INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEA
40. charger service procedures present hazards that can result in se vere personal injury or death Only trained and experienced personnel may perform service WARNING Ignition of explosive battery gasses can cause severe personal injury Do not smoke or cause any spark arc or flame while servicing batteries 2544 OVER TEMP Charger is overheating Unrecoverable battery 9115 BATT FAIL NOTE Faults 379 OVER CURR 442 or By recycling the power Battery Charger Fails to Charge 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 Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any spark or flame while servicing bat teries For 120 208 and 240 VAC battery chargers verify that the two 10 amp AC circuit breaker switches have not been tripped are in the up position If the circuit breakers are in the On position call your dealer or distributor Fom27 380 416 and 600 VAC battery chargers check the battery charger fuse s Replace if neces sary With fuses of the correct rating Fuse ampere 1 Charger s ambient tem perature is too high 2 Charger s internal cooling fan is blocked failed or air inlets are covered The battery can no longer
41. d Press the ok button The screen then shows the hour value flashing 12 15 18 21 24 MINUTE 2 50 12 15 18 21 24 HOUR 8 Press the or button okon The minute is displayed Press the The screen M 1 2 00 datesand time 7 Press the or button until the correct hour is displayed Press the ok button The screen then shows the minute value flashing 4 26 PLANNED MAINTENANCE Performing the annual planned maintenance procedures increases reliability of the transfer switch The following procedures must only be done by technically qualified personnel according to procedures the Service Manual 962 0521 If repair or component replacement is necessary call your dealer or distributor AC power within the cabinet and the rear side of the cabinet door preserits a shock hazard that can cause severe personal injury or death Incorrect installation servic por parts replacement can result in severe personal injury death and or equipment damage All corrective service proce dures must be done only by PERDIE UY qualified personnel according to procedures in the Service manual 962 0521 The transfer switch presents a shock hazard that can caus severe personal injury or death unless all AC power is removed Be sure to set the genset op ration selector switch to Stop disconnect AC line power disconnect the battery charger from its AC power source and di
42. dicated on the bottom of the screen 12 15 18 21 FLASHES INDICATES THAT AN EXERCISE IS SET FOR SATURDAY 8 Review additional set exercise periods and re turn to the Main menu To exit the Check Programs function with out reviewing all set exercise periods press the or buttons until END is dis played Press the ok button to return to the Main menu 12 15 18 21 24 a i FLASHES To review all set exercise periods repeat steps 6 and 7 until the word END is dis 4 18 played Press the ok button to return to the Main menu 12 15 18 21 Prog FLASHES NOTE If an exercise period has been pro grammed with a time only a continu ous band of s gments is displayed on the left side and top ofthe screen showing the time ofdayathe incomplete exercise period is setto begin This band of seg ments is also displayed on any other ex ercise periods scheduled for that day FLASHES If an exercise period has been pro grammed with a stop time only no spe cial indicator is displayed The stop time is simply ignored Deleting Exercise Start Stop Times While checking the programs you can also delete individual start and stop times 12 15 18 21 gt FLASHES 1 When an programmed exercise start time is displayed press the or buttons until Clear is displayed FLASHES 2 Press the ok button The New Program menu is redisplayed 12 15
43. e the TDNE timer immediately expires The TDNE timer will not begin if a Transfer Inhibit input is active Time Delay Emergency to Normal TDEN While connected to Emergency this time delay al lows utility power to stabilize before the retransfer command is issued This delay also allows the gen erator to operate under load for a minimum amount of time before transferring back to utility power This time delay starts with the transfer switch con nected to the generator and after the utility be comes available following an outage The green Utility Power Available LED is lit This time delay _ also starts when an active Test or Exercise period is ended After the delay the transfer switch can re transfer the load to the utility power source The time delay is configurable for O disabled O 1 5 10 15 20 25 or 30 minutes default 2 10 min utes If the utility fails any time during this time delay the control resets the timer and restarts it once utility power becomes available If the genera tor fails at any time during this time delay the timer expires and the normal retransfer sequence takes place If the Override pushbutton is pressed or the Over ride input is grounded while the TDEN timer is ac tive the TDEN timer immediately expires The TDEN timer will not begin if a Retransfer Inhibit input is active Time Delay Programmed Transition TDPT This feature causes the transfer switch to pause in the Neutr
44. e exercise peri od is over the Exercise LED stops flashing and remains on to signify that repeat exercise peri ods are enabled Canceling Repeat Exercise Periods With the control panel Exercise LED on steady press and hold the Set Exercise pushbutton for 5 seconds The Exercise LED flashes at a rate of twice per second for 5 seconds and then goes out to signify that repeat exercise periods are cancelled Canceling An Active Exercise Period Active exercise periods can be canceled by press ing the Override pushbutton on the control panel or by grounding the remote override input P4 2 on the back of the control panel Power Source Failure During An Active Exercise Period If either power source fails during an active exercise period the control immediately terminates the exer cise and proceeds with the automatic mode of op eration Exercise Without Load Sequence of Events 1 When an exercise period becomes active the Exerciser LED flashes at a rate of once per sec ond 2 The control signals the generator to start nd run for 20 minutes After the exercise period has ended thescontrol signals the generator to stop 4 9 4 The Exercise LED stops flashing and remains on to signify that repeat exercise periods are set unless there no repeat exercis amp peris ods If there are no repeat exercise periods the Exercise LED goes out Exercise With Load Sequence of Events 1 When an exercise period
45. enced personnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Do not wear jewelry or loose clothing Stand on a dry non conductive surface such as a rubber mat or wooden platform Before removing or replacing components remove power to the door by disconnecting the appropriate connector s for your model transfer switch _ OTPC and OHPC CHPC Connector J1 P1 on the accessory control panel BTPC Connector J10 P10 on the accessory control panel OTEC Connectors J1 removes power to the door and J2 removes power from the battery in the control panel both connectors are on the relay panel assembly Improper operation f the generator set presents multiple hazards that can cause severe personal injury or death Observe all safety precautions in your generator set manuals AWARNING Ignition of explosive battery gasses can cause severe personal injury Do not smoke or cause any spark arc or flame while d batteries Possible Cause Corrective Action No DC Output 1 Tripped DC circuit breaker 1 Correct the possible overload and reset the circuit breaker 2 Correct the possible overload and replace the fuse s as described below 3 Correct the possible overload and reset the circuit breaker 2 Blown AC fuse s 277 380 416 480 and 600 VAC bat tery chargers 3 Tripped AC circuit breaker s 120 208 and 240 VAC bat tery chargers Lo
46. enu is displayed after two seconds or by pressing the ok button 12 15 18 21 24 FLASHES 4 14 1 From the Home menu press the Menu button The Program menu is displayed FLASHES 12 15 18 21 Auto Prog 9 PROGRAM 2 Press the ok button The New Program menu is displayed 12 15 718 21 Prog FLASHES NEW PROG 3 Press the ok button The number of available programmable time periods maximum of 28 is temporarily displayed 12 15 18 21 Prog NUMBER OF FREE AVAILABLE PROGRAMMABLE 28 TIME PERIODS 4 The Starting Time Time On menu is dis played Press the ok button 12 15 18 21 24 FLASHES 5 The Hour menu is displayed Press the or buttons to set the desired exercise starting hour default 12 00 AM A line is displayed on the screen indicating the hour of the day se lected the left side of the screen is for the first half of the day AM and the top of the screen is for the second half of the day PM Press the ok button 12 as 21 24 FLASHES 6 The Minute menu is displayed Press the or buttons to set the desired exercise starting minute Press the ok button 12 19 18 24 1234567 FLASHES 7 menu is displayed for selecting the day Ofthe week the exercise is to begin default Monday Press the or buttons to select the desired day of the week A small triangle is dis played above the assigned number t
47. erify that the system nominal voltage matches what is listed on the nameplate c Check the control setting to verify that the system frequency matches what is listed on the nameplate Check the control setting to verify that the system phase setting matches what is listed on the nameplate If the Genset Power Available LED is lit a The transfer time delay may not ex pired The TDNE can be set for up to 300 seconds If you do not wish to wait until the time delay expires press the Override pushbutton VALUE Default in bold italics FUNCTION CODE VALUE FOR TDNE CODE OSeconds Disabled 5500000 f e el seconds Ze 80 Seconds eoo 120 Seconds 300 Seconds b be an active transfer inhibit If a transfer inhibit is enabled the load transfer Will Not take place until the Override push button on the control panel is pressed or the transfer inhibit input is disabled 6 4 2 If the problem persists call your dealer or dis tributor After Power Returns the Transfer Switch Does Not Return To Normal Position 1 Check to see if the Utility Power Available LED is lit If the Utility Power Available LED 1 lit a The retransfer time delay period may not have expired be set for up to 30 minutes If youdo not wish to wait until the time delay expires press the Override pushbutton FUNCTION
48. f the external exerciser is used the External Exercise On Off function must be set to On If the external exerciser is factory supplied the External Exercise On Off function is set to On at the factory If the external exerciser is not factory installed the External Exercise On Off function is set to Off Information on configuring the controlis included in Section 5 Information on the optional external exerciser is included later in this section Exercise With or Without Load The exercise with without load configuration works with both types of exercisers default without load see Section 5 When With Load is Selected the load is transferred to the genset When Without Load is selected the genset runs withino load for the duration of the exercise period Integrated Exerciser This function is standard nd is built into the control With this exerciser the exercise period is 20 min utes and it repeatS every 7 14 21 or 28 days de fault 7 days see S ction 5 The integrated exercise function cannot be used unless the External Exercise function is disabled set to 4 8 Before an exercise can begin the transfer switch must be connected to utility power and utility power must be available the green Utility Power Available LED must be lit Power Loss Backup If DC power is removed from the controkpanel the exercise clock uses a replaceable lithium battery Onan part number 416 1250
49. fter this action the control starts the TDEN timer The Test LED flashes twice per second for two seconds to acknowledge the operation and then the Test LED goes out After the TDEN timer expires the transfer Switch retransfers back to the utility the Utility Power Connected LED is lit Once the transfer switch is connected to utility power the control starts the TDEC timer After the timer expires the control energizes the start relay opening the start contact to sig nal the generator to stop Test Without Load Sequence of Events The following describes the sequence of events of an OTEC transfer switch during a test without load In this sequence of events the generator is started and runs without load for the duration of the test The utility must be acceptable during the entire test event Acceptability is determined by the active _ Source sensor undervoltage sensor If at any time the undervoltage sensor determines that the utility is not acceptable the Test is terminated Before a test can begin the transfer switch must be connected to the utility and utility power must be available 1 Verify that the transfer switch is set to test with out load 2 Verify that the green Utility Power Connected LED on the control panel is lit 3 Verify that the green Utility Power Available LED on the control panel is lit Press and hold the control panel Test pushbut ton for two seconds or ground the Remote Tes
50. he dis play for the day of the week 1 Monday 7 Sunday Press the ok button 12 15 18 21 24 FLASHES The Copy ments displayed If you do not wish to have the exercise repeat more than once a 10 11 4 15 week go to step 9 If you do wish to have the exercise repeat more than once a week go to step 10 12 15 18 21 24 a a FLASHES Press the or buttons The Store menu is dis played Press the ok button Go to step 13 uc 15 E 29 24 FLASHES To repeat an exercise more than once a week press the ok button when the Copy menu is dis played The Add day menu is displayed The day after the day selected in step 7 is dis played i is al 24 FLASHES Press the or buttons to select the desired day of the week that an exercise is to begin Press the ok button 12 15 18 21 24 FLASHES 12 Press the or buttons The Store menu is dis played Press the ok button 12 15 18 21 FLASHES Prog STORE 31 307 NOTE After setting all days of the week that an exercise is to be repeated you can use the or buttons to cycle through the days and recheck the programs When a day that has a set program is redis played it can be deleted In the menu shown below press the ok button to de lete the displayed program Prog DELETE 11 307 FLASHES 13 The New Program menu is redisplayed 12 15 18 2
51. he transfer switch must be connected to the utility power source and utility power must be available 1 Verify that the transfer switch is set to test with load 2 Verify that thesgreen Utility Power Connected LED control panel is lit 10 11 12 13 Verify that the green Utility Power Available LED on the control panel is lit Press and hold the control panel Test pushbut ton for two seconds or ground the Remote Test input to initiate the Test The Test LED flashes two times per second for two seconds ac knowledging that the test was activated Once the test period starts the LED stays on continuously The control simulates a utility power failure but the Utility Power Available LED remains lit as long as the utility is stilPavailable The control st rts T DES timer After the tim er expires the control de energizes the start relay closing the start contact to signal the gen erator t start When the generator output is acceptable the Genset Power Available LED is lit the control Starts the timer s After the timer expires the transfer Switch transfers to the genset the Genset Power Connected LED is lit The control continues to run the generator with the transfer switch connected to the genset un til the control panel Test pushbutton is momen tarily pressed or the ground is removed from the Remote Test input A
52. hen both sources are available In formation on configuring the Phase Check On Off function is included in Section 5 Return to Programmed Transition This feature can be used in conjunction with the phase check sensor If for some reason the two sources do not fall within the specified limits of the phase check sensor for a period of two minutes then the control bypasses the phase check sensor returns to the Programmed Transition sequence of operation and transfers the load If this feature is enabled the programmed transition time delay TDPT should be set greater than zero The actual setting depends on your load GENERATOR SET EXERCISER Run the generator at least once each week with at least 50 percent load if possible If you do not want to use the exerciser use the Test pushbutton as de scribed earlier in this section to test the generator set each week The control panel includes an integrated exerciser that is set by pressing the Set Exercise pushbutton In addition there may also be an optional fully pro grammable external exerciser clock installed and wired to a control input see page 4 10 If both types of exercisers are available only one exerciser can operate at a time The control panel must be configured for the type of exerciser being used This is done by setting the External Exerciser function On or Off If the integrated exerciser is used the External Exercise On Off function must be set to Off I
53. ilable Utility or genset voltage need not be present to ad just the configuration The following tables show which control functions should not be changed Table 2 1 and which func tions can be changed for your application Table 2 2 Refer to Section 5 for more details TABLE 2 1 FUNCTIONS THAT SHOULD NOT BE CHANGED Factory Setting oet for your system voltage Set for your system voltage oet for your system frequency System Nominal Voltage Table System Nominal Voltage System Nominal Frequency Set for your system 3 to On if the external exerciser option was ordered otherwise setto Off System Phase External Exercise TABLE 2 2 FUNCTIONS THAT CAN BE CHANGED Factory Setting TDES Time Delay Engine 18 Seconds Start Time Delay Normal to 10 Minutes Emergency TDEN Time Delay Emergency to Normal TDEC Time Delay Engine pue TDPT Time Delay Seconds Programmedptransition Cooldown TDELXTime Delay Elevator Seconds signal ne Without Load Test With or Without Load O O O Phase Check Transition 3 Description This section describes the control cabinet the switch mechanism and the standard and optional control features available with the OTEC transfer switch CABINET Cabinets are available in various configurations that meet UL and National Electrical Manufacturer s As
54. included on page 4 8 TEST WITH OR WITHOUT LOAD This feature allows a transfer switch operator to test the transfer switch and generator power system The test is configurable to be with load or without load A test with load initiates a load transfer A test without load just starts the generator and runs it without load 1 Verify that the transfer switch is set to test with or without load as desired see Section 5 2 To start a test press and hold the Test Pushbut ton for two seconds or ground the Remote Test input 3 To end the test momentarily press the Test pushbutton or remove the ground from the Re mote Test input NOTE When ending a test with load you can bypass the retransfer time delay TDEN and cause the immediate load retransfer by pressing the Override button The generator stops after the engine cooldown time delay TDEC Test With Load Sequence of Events The following describes the sequence of eventS of an OTEC transfer switch during a test with load this example TDPT is set to zero the phase check sensor is disabled the Transfer Inhibit and Retran sfer Inhibit inputs are inactive and TDEL 15 set to Zero The utility must be acceptable during the entire test event Acceptability is determined by the active source sensor undervoltage sensor If at any time the undervoltage sensowdetermines that the utility is not acceptable the Test is terminated Before a test can begin t
55. ing pages in clude checking On the control panel settings To check the control settings open the transfer switch door and Slideathe selector switch on the back on the coritrol panel to the Configuration Mode position Additional information on configuring the control panelis included in Section 5 GENSET POWER AVAILABLE LED GENSET POWER CONNECTED LED ACTIVE EXERCISE LED FIGURE 6 1 CONTROL PANEL TABLE 6 1 CONTROL PANEL LED INDICATORS O Utility Normal Power This indicator lights when the utility source voltage sensor has determined fhat Utility Available power is available and is within acceptable voltage limits Utility Normal Power 1 Lights constantly when the transfer switch is connected to Utility Power Connected 2 Blinks twice per second when the transfer switch has failed to connect to or disconnect from Utility Power when commanded 3 Is off when the transfer switch is not connected to Utility Power Genset Emergency Power This indicator lights when the generator source voltage sensonhas determined that Available generator power is within acceptable voltage and frequency limits Genset Emergency Power 1 Lights constantly when the transfer switch is connected to Genset Power Connected 2 Blinks twice per second when the transfer switch has failed to connect to or disconnect from Genset Power when commanded 3 Is off when the transfer switch is not connected t
56. lay To re activate the display briefly press the Menu button Up to 28 programs are available to set exercise start and stop times One program is required to start an exercise period and a second one 15 required to stop an exercise period The exerciser clock also has a built in test feature that can be used to initiate a genset start and run cycle The exerciser clock contains a lithium battery that is used as a backup power source The battery is not replaceable When the clock is running off the inter nal battery three flashing dots are displayed be tween the hour and minute values see Figure 4 3 DISPLAY MODE AUTO PROG O OR TIME INDICATORS XERCISE STATE INDICATOR ON OFF TIME OF DAY DAY OF WEEK INDICATOR 1 MONDAY 7 SUNDAY MENU SELECTION BUTTON USED TO SELECT ONE OF FOUR DISPLAY MODES ORAT O ABORT ADJUSTING PARAMETERS Unless the clock battery fails exercise programs are stored and are not lost during a power outage FLASHES FIGURE 4 3 INDICATOR OF CLOCK RUNNING OFF THE INTERNAL BATTERY Figure 4 4 illustrates the face of the exercise clock and provides information on the display and the function of the buttons The clockis programmed with the correct date and centrakUSA standard time and with the correct day light savings time settings Programming the exer ciser clock requires entering the exercise start and stop times and if necessary adjusting the ti
57. mal to Emergency TDNE Time Delay Emergency to Normal TDEN Bypass the timer and transfer thedoad immediately during an active Transfer Inhibit input e Bypass the TDEN timer and retransfer the load immediately during an active Retransfer Inhibit input e Stopthe Utility Power Connected L ED from flashing as a result of a failure to connect to or disconnect from the utility when com mand ed e Stop the Genset Power Connected LED from flashing as a result of a failure to con nect to or disconnect from the genset when commanded e Cancel an active The Program Transition TDET Elevator signal TDEL and Engine Cool Down TDEC time de lays are not affected by pressing this pushbutton Set Exercise Pushbutton This pushbuttorris only used with the integrated ex erciser and functions if the External Exercise functions disabled set to Off Information on con figuring the control panel is included in Section 5 The Set Exercise pushbutton is used to Seta delayed repeat exercise period when the pushbutton is pressed and held for five Seconds e Start an immediate exercise period that also repeats if the pushbutton is pressed momen tarily within ten seconds of starting the delayed exercise period e Cancel a repeatable exercise period if the pushbutton is pressed and held for five sec onds More information on using the integrated exerciser is
58. me as described on the following pages Exercise With or Without Load The external exercise clock does not include an ex ercise with or without load function This function must be configured using the transfer switch control panel For more information see Section 5 INDICATORS OF WHEN EXERCISES ARE SCHEDULED FOR THE CURRENT DAY SPECIAL FUNCTION INDICATORS OVERRIDE ON OFF PERMANENT ON OFF DATE MONTH DAY AND YEAR SUMMER WINTER CHANGEOVER INDICATOR SUMMER WINTER ok BUTTON USED TO CONFIRM SELECTION BUTTONS USED TO INCREASE DECREASE RESET BUTTON USED ONLY IN CASE OF EMERGENCIES TO DELETE INDIVIDUAL SETTINGS SEE PAGE 4 25 VALUES TO SCROLL THROUGH MENUS AND TO SELECT SPECIAL FUNCTIONS FIGURE 4 4 EXERCISE CLOCK FEATURES 4 10 Using the Menu Button The Menu selection button is used to select three display modes that have adjustable menus e The Clock mode is used to set the correct date and time This mode can also be used to au tomatically switch to the correct summer winter time See page 4 11 e The Program mode Prog is used to set see page 4 14 review see page 4 17 and clear exercise start stop times see pages 4 20 and 4 21 e The Manual mode Man is used to enter a 4 digit code to prevent changing settings by unautho rized personnel See page 4 24 When adjustments are completed the Home menu Auto mode is redisplayed see Figure 4 4
59. nd Stop 2 2 4 14 Checking the Programs 4 17 Erasing Clearing A Programmed ExerciSe Period 4 20 Erasing Clearing All Programmed Exercise Periods 4 21 Initiating or Overriding an Exercise Program 4 22 Selecting Permanent On Off Mode gt xd eta Oh ut ee 4 23 Adding A Security 4 24 After Programming the ExerciSer 4 25 Resetting the Timer 4 25 Planned Maintenance Sg 4 27 5 CONTROL PANEL CONFIGURATION 5 1 Accessing the Front Panel Configuration Editor 5 1 Modifying the 5 4 6 TROUBLESHOOTING 6 1 Control Panel ROIS 6 1 Troublesnodg apo Wa sees xr e 6 1 Power Q tage Occurs But Generator Set Does Not Start 6 2 Generator Set Starts During Normal Power Service 6 3 GeneratomSet Does Not Exercise 6 3 After a Power Failure the Generator Set Starts But Does Not Assume the Lo
60. nel is set to One For more information see Section 5 2 Place the generator set operation selector switch in the Remote position 3 Check the system for proper operation as de scribed the Operators Manual Resetting the Timer The Reset button should only beused in cases of an emergency Resettingtthe timer erases all existing language date and time settings Upon pressing the Res button the clock is set to 12 00 midnight Wednesday Januafy 142003 However sched uled exercise periods remain intact 1 Use a pointed object to press the Res button for approximately one second Two information 4 25 screens are displayed and the default national language is flashed 12 15 18 21 24 s a a a ENGLISH If the incorrect language iSsbeing displayed use the or button to Scroll through the avail able languages English Espanol Francais Portugal Italiano or Deutsch When the desiredilanguage is displayed press the ok buttons The year is displayed next 12 15 18 21 24 s a Press the button until the correct year is dis played and then press the ok button The month is displayed next 12 15 18 21 24 s a a Press the button until the correct month is displayed and then press the ok button The screen then shows the day value flashing 12 15 18 21 24 a 6 Press the or button until the correct day is displaye
61. ng time can only be set for 1 00 2 00 or 3 00 AM 17 Press the ok button to display the menu for set ting the month when the Winter changeover will take place Press the or buttons until the de sired month is displayed 12 15 18 21 a LI 3 12 15 18 21 24 a s a 14 Press the ok button to display the menu for set FLASHES ting the month when the Summer changeover will take place Press the or buttons until the desired month is displayed 4 13 18 Press the ok button to display the menu for set ting the week when the Winter changeover will take place Press the or buttons until the de sired week 1 thru 5 1 first week 4 fourth week 5 last week is displayed 12 15 18 21 E WEEK WI FLASHES NOTE The starting time for the winter changeover is the same time that was set in step 16 19 Press the ok button The Home menu is redis played and the appropriate summer winter symbol is displayed 12 15 18 21 91 Auto 03 01 04 Off 11 12 7 1234567 Setting Exercise Start and Stop Times Up to 28 programs can be used to set exercise start and stop times One program is required to Start an exercise period and a second one is required to stop an exercise period NOTE If the Menu button is pressed before Start Stop program is saved Escape is displayed onthe screen program settings are lost andythe Home m
62. nsfer will not take place until the Override push button on the control panel is pressed or the transfer inhibit input is disabled There may be an active TDEL Wait until the time delay has expired The TDEL can be set for up to 300 seconds FUNCTION CODE VALUE VALUE Defaultin FOR TDEL CODE bold italics 30 Seconds 120 Seconds eee 300 Seconds C Seanas Disabled o Weed e e gsm d A phase checkmay be enabled When the phase check function is enabled the genset does not assume the load until both sources are within acceptable limits of the phase _ check sensor External Exercise Clock Does Not Start An Exercise AC power within the rear side of the cabinet door presentS a shock hazard that can cause severe personal injury or death When the cabinet door is open use ex treme caution to avoid touching electrical con tacts with body tools jewelrysclothes hair etc 1 Check the control setting to verify that the Ex ternal Exercise function has been set to On 2 Check the exercise program to see if exercise periods beenset up 3 Check the exercise program to verify that both start and stop times for the exercise period have been Set up The exercise will not start if only the start time is set up External Exerciser Does Not Repeat an Exercise Check the external exercise clock Permanent On Off Mode setting
63. ntacts with tools jewelry clothes hair while servicing batteries etc Ignition of fue can cause se vere personal injury or dez 1 Verify that the operation selector switch on the plosion Do not permit any cigarette generator set control panel is set to the Remote spark pilot light arcing or oth position Check for fault indicators on the gen er possible source of ignition near the fuel erator set control system 6 2 Generator Set Starts During Normal Power Service AWARNING 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 Whenever the cabinet door is open use extreme caution to avoid touching electrical contacts with body tools jewelry clothes hair etc 1 Verify that the operation selector switch on the generator set control panel is set to the Remote position Check the Utility Power Available LED on the control panel to see if it is lit If the Utility Power Available LED is lit Check the Active Exercise LED to see if it is in an exercise period a NOTE If the exercise period occurs at an unexpected time or for an exces sive duration refer to the exerciser clock programming procedure or call your dealer or distributor b Momentary voltage dips might cause volt age sensors to initiate generator set start ing Check the utility undervoltage parame
64. nu Initiating or Overriding an Exercise Program The exercise clock has a built in test feature that can be used to initiate an exercise that hasn t been programmed or cancel a programmed exercise in process The control panel Load No Load function can be set to test the genset with or without load as desired Initiating an Exercise In the example shown below Off indicates that no exercise is currently active 12 15 18 21 Auto 03 01 04 Of 2 50 1 With the Home menu displayed simultaneous ly press the and buttons for approximately one second Override and a hand symbole are displayed on the screen In addition Off is switched to On and the exercise is initiated 12 15 18 21 m OVERRIDE On n 2 509 2 Toend the exercise Simultaneously press the and buttons for approximately one second The menu is redisplayed and is switched backto Off 4 22 12 15 18 21 Auto 03 01 04 Off 2 58 9 Overriding an Exercise In the example shown below On indicates that an exercise is currently active Auto 03 01 04 On 2 50 gt 1 Withthe Home menu displayed simultaneous ly press the and buttons for approximately one second Override and hand symbol are displayed on the screen In addition On is SWitched to Off and the exercise is stopped 24 12 15 18 21
65. o Generator Power Exerciser Enabled The following describes the Exercise Enabled BED when an exercise is enabled 1 Lights constantly when integrated repeat exercise periods have been set 2 Blinks twice per second when the Set Exercise button is pressed and held to set _ or cancel an integrated exercise period Blinks once per second when an integrated or external exercise period is active 4 Is off when no integrated repeat exercise periods are set Active Test 1 This indicator blinks at two times per second rate during the two seconds that the Test button is acknowledge that a test has been activated or when the remote test inputistgrounded 2 The indicator 4ights constantly during the test and goes out ore the test is com pleted or nomal Power has failed Power Outage Cccurs But Generator Set 2 Start the generator set using 5 start stop con Does Not Start trols If it does not crank che the starting bat teries If it cranks but does r start check the fuel supply If the problem rsists call your LAWARNING AC power within the cabinet and the dealer or distributor rear side of the door presents a shock hazard that can cause severeperSonal injury or Ignition of e death Whenever the cabinet door is open use gases can cause severe vonal injury Do extreme caution avoid fou ching electrical not smoke or cause any park or flame co
66. re ready to handle all your service needs To contact your local Cummins Power Generation 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 contact a distributor using the automated service consult the Yellow Pages Typi cally our 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 1 763 528 7229 When contacting your distributor always supply the complete Model Specification and Serial Number as shown on the generator set nameplate 2 Transfer Switch Start Up The OTEC transfer switch is preset at the factory to operate using default settings The control will oper ate the transfer switch when power is applied How ever you may wish to adjust some of the settings for better performance The transfer switch must be installed correctly with DC power present before any adjustments to the configuration can be made If the transfer switch is connected to utility power the Utility Power Con nected LED will be lit if battery power is ava
67. s disabled There may be an active TDEL Wait until the time delay has expired The TDEL can be Set for up to 300 seconds FUNCTION CODE VALUE VALUE Default in FOR TDEL CODE bold italics C 9 Seconds Disabled d A phase check may be enabled When the phase check function is enabled the genset does not assume the load until both sources are within acceptable limits of the phase check sensor System Does Not Exercise With Load 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 When the cabinet door is open use ex treme caution to avoid touching electrical con tacts with body tools jewelry clothes hair etc 1 Check the control setting to verify that the Exer cise With Without Load function has been set to With Load 2 the control has been set to Exercise With Load The transfer time delay may not have ex pired The TDNE can be set for up to 300 seconds If you do not wish to wait until the time delay expires press the Override pushbutton FUNCTION CODE VALUE VALUE Default in FOR TDNE CODE bold italics e O O 0 Seconds Disabled Of 2sm e e O e 2 2 9 e sens e o o e 30 Seconds e 120 Seconds e e e 300 Seconds b There may be an active transfer inhibit If a transfer inhibit is enabled the load tra
68. sconnect the starting battery negative lead first before servicing AWARNING Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any spark arc or flame while servicing batteries 1 Disconnect All Sources of AC Power A Disconnect both AC power sources from the transfer switch before continuing Tum the generator set operation selector switch to Stop The selectomswitch is located on the generator set control panel B If there is an external battery charger disconnect it from its AC power source Then discon nect the set starting battery negative is lead first 2 Clean A Thoroughly dust and vacuum All controls meters switching mechanism components interior bus work and connecting lugs B Close the cabinet door and wash exterior surfaces with a damp sponge mild detergent and water Do not allow water to enter the cabinet especially at meters lamps and switches 3 Inspect A Check buswork nd supporting hardware for carbon tracking cracks corrosion or any other types of deterioration If replacement is necessary call your dealer or distributor B Check stationary and movable contacts If contact replacement is necessary the procedures describedin the Service Manual 962 0521 C Check system hardware for loose connections Tighten as indicated in step 4 D Check all control wiring and power cables especially wiring between or near hinged door
69. sition On Off OO OPO 5 T D Elevator Post Transfer Delay On Off Every 7 Days 4 8 Every 14 Days Every 21 Days Every 28 Days Exercise Repeat Interval O O e O e MODIFYING THE CONFIGURATION The control has been configured at the factory and does not require additional adjustments default settings are shown in bold italics in Table 5 1 How ever you may wish to adjust some of the settings for better performance Incorrect settings can result in the transfer switch failing to operate correctly Only authorized trained personnel should make changes to the control function settings Exter nal Exercise System Nominal Voltage System Nominal Frequency and Single Phase Three Phase settings are made at the factory and should not require any additional adjustments 1 Slide the selector switch to the Configuration Mode position as described on page 5 1 12345678 P4 SWITCH IN AUTOMATIC MODE TDES is always the first function shown when entering Configuration Mode Press the Test pushbutton to scroll through the various control function codes displayed with the first five LEDs see Table 5 1 The black filled circles indicate which LEDs are lit for the function and value codes listed Once the desired function issSelected press the Override pushbutton to change the associ ated value code displayed with the last three
70. sociation NEMA requirements Each cabinet OPTIONAL CONTROL EXTERNAL PANEL EXERCISE CLOCK includes an identification label The standardscabi net offerings are e Type 1 Indoor General Purpose Type 3R Outdoor Rainproof e Type 4 Outdoor Watertight Type 12 Indoor Dust Tight Examples of cabinets are shown in Figures 3 1 thru 3 4 AUTOMATIG TRANSFER TB1 SWITCH 1 TRANSFER SWITCH HANDLES J1 J2 POWER TRANSFORMER 600 VOLT UNITS ONLY GROUND RELAY OPTIONAL LUGS TB2 ASSEMBLY BATTERY CHARGER FIGURE 3 1 INTERIOR COMPONENTS 40 125 AMP SWITCH TYPE 1 CABINET 3 1 EXTERNAL 1 SWITCH OPTIONAL BATTERY CONTROL EXERCISE CHARGER CLOCK dica x ae See XP M 4 o ct am ied p 74 71777 N NE CERTES ES rte esed diet Sa CO a A nan DOE ON GAAP Mi me rs A a ere en TA ASSEMBLY CRIME INE GROUND TB2 LUGS TRANSFER POWER SWITCH TRANSFORMER 600 VOLT UNITS ONLY FIGURE 3 2 INTERIOR COMPONENTS 150 225 AMP SWITCH TYPE 4 CABINET OPTIONAL AUTOMATIC TRANSFER EXTERNAL CONTROL EXERCISE SWITCH PANEL CLOCK s OPTIONAL BATTERY J2 ASSEMBLY CHARGES 2 TB2 TRANSFER POWER SWITCH TRANSFORMER HANDLES 600 VOLT UNITS ONLY FIGURE 3 3 INTERIOR COMPONENTS 260 AMP SWITCH TYPE 3R AND 12 CABINET 3 3 OPTIONAL AUTOMATIC EXTERNAL TRANSFER NEUTRAL PANEL CLOCK LINEAR AC TUATOR OPTIONAL
71. t input The Test LED flashes twice per second for two seconds acknowledging that the test was activated Once the test period Starts the Test LED stays on continuously The control de energizes the start relay clos ing the start contact to signal the generator to start When the genset Starts and produces power the amber GensetPower Available LED lights The control contin es to r n the generator with out load until the control panel Test pushbutton is momentarily pressed or the ground is re moved from the Remote Test input After thg control panel Test pushbutton is mo mentarily pressed or the ground is removed from the Remote Test input the control flashes the Test LED twice per second for two seconds toyacknowledge the operation and then goes out s The control energizes the start relay opening the start contact to signal the generator to stop SENSORS Utility Sensor The utility sensor monitors all phases of the utility for undervoltage conditions Both the pickup and dropout set points are adjustable The set points are listed in Table 4 1 Refer to Section 5 for information on how to make adjustments TABLE 4 1 UTILITY UNDERVOLTAGE SET POINTS Undervoltage Pickup of Nominal Undervoltage Dropout of Nominal Available Set Points 95 90 90 85 80 70 NOTE If the utility undervoltage pickup is set at 90 then the dropout has to be set lower than 90 Figure 4 2 ill
72. ter settings on the control panel Increase the TDES setting If the Utility Power Available LED is Check the control setting to verify that the system nominal voltage matches what is listed on the nameplate a Check the control setting ta verify that the System frequency matches what is listed on the nameplate c Check the control setting to verify that the system phase setting matches what is listed on the nameplate Check the control setting to verify that the utility undervoltage dropout point is set low er than the4pickup set point If the problem persists call your dealer or dis tributor 6 3 Generator Set Does Not Exercise 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 Whenever the cabinet door is open use extreme caution to avoid touching electrical contacts with body tools jewelry clothes hair etc 1 Verify that the operatiorrselector switch on the generator set control panel to the Remote position If the optional external exerciser is installed verify that the External Exercise function has been set to On Check th Exercise LED on the control panel to see af it is lit If the Exercise LED is not lit no exercise pe riod has been set Refer to the exerciser programming procedure for information on setting an exercise a If the Exercise LED is lit but not
73. tery charger s digital display V is e oltages within the chafging sys see Table 1 Overload conditions or equipment fail tem present 222 etr cal Shack Bel d ey A ures may require additional troubleshooting see personal injury or death Discon nect all sources of AC and DC power from the Loss of AC Power battery charger before servicing 1 Disconnect the battery i from AC power When there is a loss of power the battery charger and the battery relay contacts announce this fault as an AC power loss Since the charger is no longer powered noth 2 Unscrew the fuse holders from the front of the ing is displayed on the digital display battery charger Replacing Fuses Check the fuses and replace the blown fuses s When replacing a blown fuse on battery charger 4 Reinstall the fuse holders models that use them be sure to use a fuse of the same rating and type Do not use fuses of a higher 5 Reconnect the battery charger to AC power and rating Fuses must be UL and CSA certified Re reconnectthe charger to the battery TABLE 2 TROUBLESHOOTING PROCEDURES 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 charger service procedures present haz ards that can result in severe personal injury or death The following procedures are to be performed only by trained and experi
74. tically by the transfer switch control Manual operation of the switch is also pos sible Refer to Manual Operation in Section 4 Auxiliary Contacts Auxiliary contacts are provided on the utility and genset sides of the transfer switch see Figure 3 9 They are actuated by operation of the transfer switch during transfer and retransfer The utility auxiliary contact switch is actuated when the trans fer switch connected to the utility The genset auxil iary contact switch is actuated when the transfer switch is connected to the genset The auxiliary contacts have current ratings of 10 amperes at 250 VAC The contacts are wired to terminal block TB1 UTILITY AUXILIARY CONTACTS GENSET AUXILIARY CONTACTS FIGURE 3 9 AUXILIARY CONTACTS OPTIONS Float Battery Charger Option A float charge battery charger Figure 3 10 regu lates its charge voltage to continuously charge with out damage to the battery As the battery ap proaches full charge the charging current automat ically tapers to zero amperes or to steady state load on the battery Ox Am 10 BATTERY CHARGER 10 Amp 12 Volt BATTERY CHARGER 2 Amp 12 24 Volt 2 AMP CHARGER 10 AMP CHARGER FIGURE 3 10 BATTERY CHARGERS Three chargers are available One battery charger is rated for 2 amperes at 12 or 24 VDC One battery charger is rated for 10 amperes at 12 Th oth er battery charger is rated for 10 amperessat 24 VDC The 2 ampere battery
75. ton to set the correct year Press the ok button to display the Month menu 12 15 18 21 MONTH FLASHES Press the or button to set the correct month Press the ok button to display the Day menu 12 15 18 21 24 FLASHES Press the or button to set the correct day Press the ok button to display the Hour menu A small triangle is displayed above the as signed number in the display for the day of the week 1 Monday 7 Sunday 12 15 18 21 24 FLASHES TRIANGLE Press the or button to set the correct hour A line is displayed on the screen indicating the hour of the day selected theWeft side of the screen is for the first half of the day AM and the top ofthe screen is forthe second half of the day PM Press the ok button to display the Minute menu 12715 418 21 24 FLASHES MINUTE Press the or button to set the correct min Press the ok button to display the Sum mer Winter menu 4 12 12 15 18 21 24 FLASHES NOTE If you do not wish t6 set the clock for automatic summer wWinter changeover at this time press the or button is displayed on the screen Press the button to return to the Home menu 12 15 18 21 FLASHES 9 P ress the ok button to display the No Summer Winter menu FLASHES 10 Press the or button to display the With Sum mer Winter menu FLASHES 11 Press the ok b
76. transfer and retransfer of the load are the two most basic functions of a transfer switch TRANSFER SWITCH FUNCTION Automatic transfer switches capable of automatic operation without operator intervention perform the basic function of transferring the load to the avail able power source The controller monitors each source for allowable voltage and frequency range This automatic transfer switch capable of automat ic operation without operator intervention is de gt 2004 Cummins Power Generation All rights reserved signed for utility to genset applications In utility to genset applications the transfer switch performs the following functions Senses the interruption power Sends a start signal to the genset Transfers the load to thie genset Senses the return of utility power Retransfers the load to the utility oends a stop signal to the genset o0 Wh NORMAL POWER OVERCURRENT PROTECTIVE DEVICE CUSTOMER SUPPLIED OVERCURRENT PROTECTIVE DEVICE CUSTOMER SUPPLIED GENERATOR SET EMERGENCY POWER FIGURE 1 1 LOAD TRANSFER SWITCH TYPICAL FUNCTION cummins Onan and PowerCommand are registered trademarks of Cummins Inc MODEL IDENTIFICATION Identify your model by referring to the Model and Specification number as shown on the nameplate Electrical characteristics are shown on the lower portion of the nameplate see Figure 1 2
77. trol sys tem that there is an impending transfer or retransfer i e the elevator is going to see a brief power fail ure This delay is disabled during an actual source ure If the timer is set for more than 0 seconds then the control activates the elevator pre transfer out put and time delay prior to transferring the transfer switch between two live sources If the control is ina Test or Exercise sequence the control adds an additional delay prior to activating the transfer and retransfer commands After the TDNE and or TDEN time delay expires the control activates the Elevator output and startsthe FDEL timer The output relay has tw normally open and two normally closed contacts rated 10 amps at 600 volts When the timergexpires the control issues the transfer or retransfer command When the timer is inactive or expires the control deactivates the relay output The Elevator Pre transfer Time Delay is configur able tor Ox disabled 1 2 3 5 30 120 or 300 sec onds default O seconds Transfer Inhibit and Retransfer Inhibit do NOT affect or delay the elevator pre transfer delay while it is ac tive The Override pushbutton or Override input has no effect on this time delay The OTEC control also includes a feature called Elevator Post Transfer Delay that keeps the eleva tor output active for the same TDEL time period af ter the transfer switch transfers For more informa tion see Elevator
78. tting the Timer on the following page the exercise timer can no longer be activated without a valid PIN code The device must replaced 1 From the Home menu press the Menu button The Program menu is displayed ELASHES 104 Prog PROGRAM 2 Press the button twice The Date Time menu is displayed followed by the Manual menu 4 24 FLASHES 12 15 Auto Prog C Man MANUAL 18 21 FLASHES NOTE the or button is pressed now the message End is displayed Press the ok button to return to the Home menu 12 15 18 21 224 1 L END 4 Press the ok button to display the No PIN menu FLASHES 5 Press the or buttons to display the With PIN menu FLASHES 6 Press the ok button to display the PIN Number menu NOTE If you choose not to enter a 4 digit access code at this time the only way to exit Manual mode is to press the reset Res button 12 15 18 21 FLASHES 7 Press the or buttons to enter the first digit of your 4 digit access code 8 Press the ok button Then press the or but tons to enter the second digit of your 4 digit ac cess code 9 Repeat step 8 for the third and fourth eg of your 4 digit access code 10 Press the ok button The Home menu is then redisplayed After Programming the Exerciser Clock 1 Make sure the External Exercise function on the transfer switch control pa
79. ushbutton on the control panel is pressedythe retransfer inhibit input is disabled or the genset fails If the genset fails retransfer inhibit IS ignored Pressing the Override pushbutton on the control panel bypasses the retransfer inhibit input and by passes the TDEN The TDNE runs if the retransfer inhibit input is disabled 2 B RMT REMOTE TEST TRANSFER INHIBIT oojo RETRANSFER INHIBIT aN FIGURE 3 7 TB2 CONNECTIONS FOR RETRANSFER INHIBIT Remote Test Input The transfer switch may be wired for a remote test input The switch is used to start and stop manually initiated system tests As with the control panel Test pushbutton the remote test input can be configured to test with or without load More information on testing is included in Section 4 A remote test input is set up by connecting a dry voltage free contact between TB2 5 and TB2 8 Closing the contact starts a test and opening the contact cancels the test The Test LED flashes to signify the start of a test and stays on during the test Closing the contact causes the transfer switch to sense a simulated utility power failure and sends a start run signal to the genset If the control is set up to test with load the load is transferred to the genset when the genset becomes available The Utility Power Available LED remains on to show that the utility did not fail 2 B RMT REMOTE TEST T
80. ustrates how the pickup and dropout settings work Example using Default Settings for Nominal Voltage of 240 VAC Nominal Setpoint 240V Drop out Setting 194V Pick up Setting 216V 90 nof Nominal 85 of Nominal FIGURE 4 2 0NDERVOLTAGE SENSING Generator Sensor The generator sensor is a single phase sensor that monitors undervoltage and underfrequency condi tions All the pickup and dropout settings are fixed and are not adjustable The genset undervoltage and underfrequency set points are listed fable 4 2 TABLE 4 2 GENSET UNDERVOLTAGE AND UNDERFREQUENCY SET POINTS Description gt SetPoint Undervoltage Pickup 90 of Nominal Undervoltage Dropout 75 of Nominal j Underfrequency Pickup 90 of Nominal i Underfrequenc Dropout 850 of Nominal Phase ChecksSensor The phase scheck sensor can be enabled set to On for pplications that require a fast transfer of a load b tweenitwo live sources both power source avail able LEDs are lit The phase check sensor deter mines when the relative phase difference less than 25 degrees and approaching 0 and the frequency difference less than 1 Hz of the two sources are within specified limits When all conditions are met atransfer is initiated If enabled the phase check 4 7 sensor is activated after all time delays have ex pired just before the transfer switch transfers the load and only w
81. utton to display the World Area menu FLASHES 12 Either select one of the world areas that has 12 15 18 21 24 been programmed for automatic time correc ALME tion or else set up your own changeover times FLASHES NOTE With the Daylight Savings Time pro gram set for North America e The first Sunday in April moves the time forward one hour e The last Sunday in October 15 Press the ok button to display the menu for set moves the time back one hour ting the week when the Summer changeover will take place Press buttons until the f you wish to select one of the world areas desired week 1 thru Me first week 4 fourth Europe GP P SF GR TR USA CAN week 5 last week i displayed that has been programmed for automatic time correction press the or buttons until the correct world area is selected Go to step 19 15 1 2 b 3 9 WEEK SU FLASHES 12 15 18 21 a 3 Li FLASHES EUROPE 16 Rresstthe ok button to display the menu for set 11 10 ting the hour of the day when the Summer changeover will take place Press the buttons until the desired hour 1 thru 3 is dis played 12 15 18 21 If you wish to set up your own changeover times continue with step 13 FLASHES 13 To set up your own changeover times press the or buttons from the World Area menu until the word Free is displayed NOTE The starti
82. ve that refer to the 10 amp bat tery charger Insert this supplement inside the front cover of the manuals listed above Page 1 of 6 DESCRIPTION The 15 12 ampere battery charger is rated for 15 amperes at 12 VDC or 12 amperes at 24 VDC There are two types of 15 12 amp PowerCommand battery chargers see Figure 1 All 15 12 amp bat tery chargers have a 20 amp DC circuit breaker switch on the front of the battery charger The 120 208 and 240 VAC battery chargers include two 10 amp AC circuit breaker switches and a circuit break er guard while the 277 380 416 and 600 VAC bat tery chargers include two AC fuse holders Control Panel The battery charger control panel includes a digital STATUS LED CONTROL 120 208 AND 240 VAC BATTERY CHARGERS CIRCUIT BREAKER FAULT ALARM OUTPUT IN CONNECTOR gt 20 AMP DC OUTPUT CIRCUIT BREAKER _ SWITCH SHOWN IN SON POSITION SENSOR CONNECTOR 277 380 416 480 AND 600 VAC BATTERY CHARGERS HOLDERS OPTIONAL BATTERY TEMPERATURE display a RESET button and an LED status indica tor see Figure 2 he 2 line x 16 character digital display dis plays menus and faults e The RESET button is used to select menu op tions and to clear fault messages e The status LED is displays the appropriate color for the following conditions Green On solid indicates unit is charging Amber On
83. wDC O tput 1 Faulty battery 1 Replace the battery 2 Charger failure 2 Call a service representative High DC Output Charger failure Call a service representative Page 6 of 6 Table of Contents SECTION TITLE PAGE SAFETY PRECUATIONS iii 1 INTRODUCTIONS rr veia t Dis 1 1 Operator s Manual eR es 1 1 Transfer Switch Application mh e n n n 1 1 Transfer Switch Function 7 1 1 Model Identification 1 2 How to Obtain Service 1 2 2 TRANSFER SWITCH START 2 1 3 DESCRIPTION 2 e RA ORE E XO EAS 3 1 Dla a 2 5 ee de io an 3 1 Control Panel c NN eC 3 5 Control Function LEDS ise iN Dh bea 3 5 ATS Status LEDS EN gency dee wid oe 3 6 Membrane Pushbuttons 3 6 Electronic Control System 7 3 7 Transfer Inhibit Input 3 7 Retransfer Inhibit Input 22 2 Tm vulga Aces 3 7 Remote Test Input
84. which is located on the cabinet door If it is necessary to contact a distributor regarding the transfer switch always give the complete Mod el Specification and Serial number This informa tion is necessary to properly identify your unit among the many types manufactured IMPOR Mode amp Serial No Required When Ordering Parts Modele amp No Serie Requis Pour Commander Des Pieces CURRENT RATING Vot tage Frequency Poles Appi FEATURES WIRING DIAGRAM BUILT IN COMPLIANCE WITH NFPA 70 AUTOMATIC TRANSFER SWITCH FOR EMERGENCY SYSTEMS For Electrical Equipment Only Pour Material Electrique Se liment FIGURE 1 2 NAMEPLATE The model number isanade up of code segments that designate vatious features or options OTECA 00000 1 2 3 Serial Number Spec A 4 5 1 OTEC Open transition transfer switch 2 Ampere Rating A 40 70 125 B 150 225 260 C 300 400 600 D 800 1000 3 Assigned spec number issued for each spe cific combination of a cessories voltages fre quency and standards codes This number is only repeated for standard product 4 Serial Number A unique number assigned to the transfer switch 5 Specification etter advances with production modification HOW TO OBTAIN SERVICE When the transfer switch requires servicing con tact yourmearest Cummins Power Generation dis tributor zFactory trained Parts and Service repre sentatives a
85. within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal injury or death When the cabinet door is open use ex treme caution to avoid touching electrical con tacts with body tools jewelry clothes hair etc Transfer Inhibit Input Atransfer inhibit input is set up by connecting a diy voltage free contact between TB2 6 and 2 8 Closing the contact enables the feature andgopen ing the contact disables it aN 2 B RMF REMOTE TEST TRANSFER INHIBIT DIDID RETRANSFER INHIBIT ___ Ow COMMON ime O pu FIG RE 3 6 TB2 CONNECTIONS FOR TRANSFER INHIBIT 3 7 This feature is used to control load transfer to gen sets When enabled load transfer will not take place unless the Override pushbutton on the control panel is pressed or the transfer inhibit input is dis abled Pressing the Override pushbutton on the control panel bypasses the transfer inhibit input and by passes The runsfif thestransfer inhibit input is disabled Retransfer Inhibit Input A retransfer inhibit input iS up by connecting dry voltage free cont ct between TB2 7 and TB2 8 Closing the contact enables the feature and opening the contact disables it This feature is used to prevent the ATS from auto matically transferring the load back to the utility When enabled load transfer will not take place un less the Override p

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