Home

OT III 962

1. a s nen 7 5 7 7 TROUBIESNOOUNG 7 8 8 SCHEMATICS AND WIRING DIAGRAMS 8 1 Mother Board 300 3953 Utility to Generator Set 8 3 Mother Board 300 3267 Utility to Utility and Generator Set to Generator Set 8 4 Mother Board 300 3090 Utility to Generator Set 8 5 626 1762 Sheet 1 of 5 UE ae RR S agros 8 6 626 1762 Sheet2 0f 5 isses REA lt 8 7 626 1762 Sheet 3 of 5 cede ated ended o x ded ore ce ea tU eR acd Eun did dr us 8 8 626 1762 Sheet 4 of 5 es eod RED Dir s pA E e RO Ra 8 9 626 1762 Sheet 5 Of 5 EP RS TREES 8 10 Open Construction Wiring Diagrams 8 11 AWARNING INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH SEVERE PERSONAL INJURY AND OR EQUIPMENT DAMAGE SER VICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND OR MECHANICAL SERVICE y Power ii Redistribution or publication of this document o Generation by any means is strictly prohibited Safety Precautions This manual includes the following symbols to indi cate potentially dangerous conditions Read the manual carefully and know when these conditions ex
2. 3 1 Transfer Switch Does Not Retransfer 3 2 Source 1 Voltage Sensor Does Not Sense Voltage 3 4 Transfer Switch Does Not Transfer 3 5 Source 2 Voltage Sensor Does Not Sense Voltage 3 7 Generator Set Does Not Crank Two Wire Start 3 8 Generator Set Does Not Crank Three Wire Start 3 9 4 TRANSFER SWITCH ASSEMBLY 4 1 General 4 1 Disconnect AC Power Orest ERR CR PERI Ed 4 1 AC Power When Finished 4 1 Linear Actuator Removal and Replacement 40 to 125 Amperes 4 1 Block and Crossbar Removal and Replacement 40 to 125 Amperes 4 4 Auxiliary Switch Removal and Replacement 40 to 125 Amperes 4 7 Linear Actuator Removal and Replacement 150 to 260 Amperes 4 9 Block and Crossbar Removal and Replacement 150 to 260 Amperes 4 12 Auxiliary Switch Removal and Replacement 150 to 260 Amperes 4 15 Linear Actuator Removal and Replacement 300 to 600 Amperes 4 17 Block and Crossbar Removal and Replacement 300 to 600 Amperes 4 20 Auxiliary Switch Removal and Replac
3. m E N m Y ce OW S es 1 1 m N m m m a m m t 2 CONTROL PRNEL 18 K1 9 51 amp 1 n N 2 T c Y K1 B 512 16 29 4 m 1 DS2 2 Tt T 7 T J7 2 T2 x2 Edo MTS m deccm UE un J2 9 K2 B T T1 X2 Pn e Pe F GND b TB4 4 4 112 TS T6 184 5 N 64 6 29 xm me m T gt x 77 TE E m1 RED 27 18 3 9 S9 NO TB4 1 2 15 16 184 2 MI WHT 512 TB4 3 SOME UNITS USE TWO CAPACITORS SEE 626 1690 D FOR COMPLETE WIRING 13 14 13 14 1 1 s SEE SHEET 3 E FOR PRIMRRY 5 CONNECTIONS T2 X1 SEE SHEET 3 FOR PRIMARY CONNECTIONS T84 S5 T84 2 STANDARD WIRING NOTES TPG THRU 1 ARE 25 INCH INSULATED 626 1762 FASTON TERMINALS FOR ACCESSORY CONNECTIONS sh4of5 Ais CUSTOMER CONNECTION TERMINAL BLOCK SEE SHEET 1 FOR DETAILS MODIFIED 626 1762 SHEET 4 OF 5 Redistribution or publication of this document by any means is strictly prohibited Power 8 9 I Teration REAR VIEW OF DOOR LEFT SIDEWALL THIS IS A REPRESENTATIVE GENERIC As SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING REFER TO THE ps2 a POWER SENTRY CONTROL UE 5 SHEET SCHEMATIC AND WIRING DIAGRAM pras r2 12 PACKAGE THAT WAS INCLUDED WITH YOUR DS4 GND 3
4. Power Generation Use care when removing the block and cross bar assembly from the base Carefully disengage the cross bar from the auxiliary switch lever to avoid cracking the switch lever Replacing the Block and Cross Bar Assembly 1 Clean all current carrying surfaces with a wire brush 2 Hold the block assembly in position on the base and check the alignment of the auxiliary switch lever When the main switch contacts are closed the auxiliary switch lever must be aligned vertically as shown in Figure 4 3 Move the auxiliary switch lever as required to get correct alignment 3 Secure the block assembly to the base with round head machine screws 2 lock washers 2 and flat washers 2 Tighten the screws to 25 to 30 in lbs 2 8 to 3 4 Nem 4 Install the power source supply wires and se curely tighten the lug terminals 5 Connect the control wiring leads to the corre sponding power source terminals Control wires are marked NORM A B C or EMER A B C for identification 6 Apply a thin coat of electric joint compound be tween the mating surfaces of the jumper bus bars braided strap connector and load bus bars 7 Install the jumper bus bars and secure to the switch assemblies with hex head machine screws and spring washers Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem torque 8 Secure the jumper bus bars to each load bus bar using a hex head machine screw ring ter minal flat washer lock washe
5. 24 24 24 24 24 24 12 VDC Coil 12 VDC Coil 12 VDC Coil 12 VDC Coil Power Generation Installed Not Wired Emergency Connected Relay Normal Connected Relay Emergency Source Available Relay Normal Source Available Relay Installed Not Wired Emergency Relay Normal Relay Genset Run Relay Installed Not Wired Emergency Relay Normal Relay Genset Run Relay 5 12 Redistribution or publication of this document by any means is strictly prohibited gt w M Alarm Module Option The optional alarm module Figure 5 13 provides an audible indication that the transfer switch has transferred to the source 2 power source A push button on the alarm module provides a means to silence the horn The Alarm lamp indicates that the transfer switch is in the Source 2 Connected position If the horn is silenced the Horn Silenced lamp will also light Both lamps will stay lit until the transfer switch moves from the Source 2 Connected position to the disconnected neutral or Source 1 Connected position Standby Set Start Sequencer Option The optional standby set start sequencer Figure 5 14 is available and applicable only on genera tor set to generator set transfer switches In dual standby applications the power cables from two generator sets are connected to the source 1 and source 2 lugs of a generator se
6. TRANSFER SWITCH Dag 5 4 1515 TB3 11 ERES TB3 12 9 9 M4 1 o M4 2 TB3 13 Ho 19 TB3 17 514 13 T83 25 12 12 SIGNAL 13 13 M3 19 MODULE 14 14 T83 18 15 15 TB3 24 16 16 13 2 o S13 4 TB3 14 17 17 TB3 23 TB3 16 9 39 SEE SHEET 3 FOR 20 20 REAR WALL OF CABINET 183 29 INSTALLATION OF JUMPERS c CC MEE 83 21 ON 11 S51 E d TRANSFER SWITCH T3 x2 T3 X1 55151 26 261 T83 3 27 7 1 EXERCISE Hr cie Bape TB3 5 Bo 30 TB3 6 MODUI TB3 7 e C NC NO INC NC NO eetet CONTROL PANEL CT1 X4 GND M3 2 M3 1 1 CT3 X1 e Bst T3 H2 TB4 2 784 4 TB4 3 N E U T 15 16 R 512 TPB t 13 14 K3 6 K3 9 J2 7 NC J N0 NCT NO NC J NO S14 C 33 T147 a 1 lt nm e 5 SEE SHEET FOR PRIMARY CONNECTIONS H4 H3 H2 Hi J 13 3 513 7 513 11 WIRING OF OPTIONS NOTES A THRU TP10 ARE 25 INCH INSULATED FASTON TERMINALS FOR ACCESSORY CONNECTIONS VN ROUTE LOAD POWER CABLES THROUGH CURRENT TRANSFORMERS 626 1762 A PHASE CT2 B PHASE CT3 C PHASE N CUSTOMER CONNECTION TERMINAL BLOCK MODIEI D SEE SHEET 1 FOR DETAILS 626 1762 SHEET 5 OF 5 Powc r 8 10 e Redistribution or publication of this document f Y fr L Lt Generation by
7. Genset 1 Running Genset 2 Running These relays are not affected by the Elevator Signal delay They respond directly to signals from the Power Sentry The Genset 1 and Genset 2 Running relays are en ergized when their respective power sources are producing adequate power Power Generation 5 10 6 Timing Delay o Seconds Program Transition SC1583 FIGURE 5 8 PROGRAM TRANSITION MODULE Signal Module No rmDelay 16 Timing 5 1584 Delay Seconds FIGURE 5 9 SIGNAL MODULE Redistribution or publication of this document by any means is strictly prohibited Y lt All relay contact connections are made at Re fer to sheet 1 of your schematic and wiring diagram package To set the time delay align the slot on the poten tiometer with the desired marking on the faceplate Figure 5 9 If a time delay is desired make sure that the Delay No Delay switch is in the Delay position The Signal Module option is not available on transfer switches that are equipped with 3 Wire Start mod ules Float Battery Charger Option The optional float charge battery charger Figure 5 10 regulates its charge voltage to continuously charge the battery As the battery approaches full charge the charging current automatically tapers to zero amperes or to steady state load on the battery There are two chargers available One battery charger is rated for
8. Three wire starting only The Auto Stop Handcrank switch on the 3 Wire Start modules AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death For this reason do not touch or allow clothing tools or jew to contact exposed electrical terminals whenever the cabinet door is open Make sure you are standing on a dry insulating surface Three wire starting only The Auto Stop Handcrank switch on the 3 wire start module should be in the Auto position Check the source selector switch on the cabi net door to make sure it is in the Auto position Check the change over clock to verify the change over schedule The procedure for checking the change over program is de scribed under Programming the Change over Clock If a change over is incorrectly programmed re fer to the change over clock programming pro cedure Momentary voltage dips can cause voltage sensors to initiate generator set starting should be in the Auto position Check for over crank condition See Operation Section Generator Set Does Not Start When a Change over Is Scheduled 3 Start the generator set using its start stop con 1 Two wire starting only The operation selec trols The Auto Stop Handcrank switch on the 3 Wire Start module must be in the Handcrank position If it does not crank check the starting battery If it cranks but doe
9. AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the block and crossbar assemblies for 40 to 125 ampere switches Removing the Block and Cross Bar Assembly Normal or Emergency 1 Remove the linear actuator as described in the Linear Actuator Removal and Heplacement section for 40 to 125 ampere switches Follow steps 1 6 in the Removing Actuator section 2 Remove the round head machine screws and flat washers that secure the interlock bar to the interlock arms see Figure 4 3 and remove the interlock bar 3 Disconnect the control wiring leads from the jumper bus bars 4 Remove the hex head machine screws ring terminals flat washers lock washers and nuts that secure the jumper bus bars see Figure 4 3 to the load bus bars 5 Remove the hex head machine screws and spring washers that secure the jumper bus bars to the block assemblies and lift off the jumper bus bars 6 Remove the control wiring leads from the pow er source terminals Figure 4 4 7 Loosen the lug terminal screws and remove the power source supply wires from the lug termi nals 8 Remove the two round head machine screws lock washers and flat washers that secure the block assembly to the base and carefully re move the assembly
10. For normal operation there isa jumper across terminals 5 and 6 Load Shed The Load Shed function is used to disconnect the load from an available Standby source in order to reduce the power consumed from that source When the load shed function is initiated the transfer switch is moved to the neutral position SC 1573 3s The load shed function is initiated by closing a set of FIGURE 7 4 REMOTE CONTROL CONNECTIONS normally open contacts across terminals 7 and 8 of TB2 If the load shed signal is removed the switch will transfer back to the Standby source if the Standby source is available TABLE 7 1 AUXILIARY RELAY OPTIONS When load shedding is in effect local or remote me selection of Normal power will cause retransfer to Ol DSA e0 24 Coil Emergency Connected Relay the Normal source if the Normal power 24 VAC Coil Normal Connected Relay source is available 24 VAC Coil Emergency Source Available Relay Refer to sheets 1 2 and 5 of your schematic and 24 VAC Coil Normal Source Available Relay wiring diagram package Auxiliary Relays Option Optional auxiliary relays provide contacts for ener gizing external alarms remote indicators and con trol equipment such as louver motors and water pumps Connections to the auxiliary relays are made direct ly to the relay terminals The terminals accept wire sizes from one 18 AWG wire to two 12 AWG wires All relays have two normally open and two nor
11. Transfer Switch Application GENERATOR i i SET 2 This transfer switch enables two generator sets SC1101 running at alternate times to provide power to a FIGURE 5 1 LOAD TRANSFER SWITCH load The transfer and retransfer of the load are the TYPICAL FUNCTION two most basic functions of a transfer switch The transfer switch may be equipped with an op tional change over clock which is programmed to alternately run and connect one generator set for a selected time and then to run and connect the other generator set for a selected time If one of the generator sets fails to operate within a selected range of voltage and optionally frequen Cy the transfer switch automatically starts and con nects the other generator set Figure 5 1 shows generator set number 1 con nected to the load Automatic transfer switches control transfer of the load to the Normal source 1 power source or to the Emergency source 2 power source without oper ator involvement gt GA Pow r 5 1 Redistribution or publication of this document di Generation by any means is strictly prohibited CABINET The standard cabinet meets the requirements of the National Electrical Manufacturers Association NEMA for a UL Type 1 cabinet This type is desig nated as a general purpose indoor cabinet Items on the door of a typical cabinet are shown in Figure 5 2 Indicator Lamps There are four indicator lamps on the cabinet d
12. fer to sheet 1 of your schematic and wiring diagram package and to the Open Construction Wiring Dia grams sheet in Section 8 OPTIONAL CONTROL MODULES AND ACCESSORIES Optional Control Modules include e 3 Wire Start e Program Transition e Signal Module Exerciser clock utility to generator set trans fer switch e Change over clock generator set to genera tor set transfer switch Phase Sequence Balance Monitor e Standby Set Start Sequencer generator set to generator set transfer switch Optional accessories include e Battery charger Auxiliary relays Load Shed function Meter package Auto Manual switch 600 Volt adapter transformer T4 Alarm Module II 1 Jn 4 ii pr ES 1688 FIGURE 2 3 TERMINAL BLOCKS Power Generation Redistribution or publication of this document by any means is strictly prohibited Three Wire Start The 3 Wire Start module Figure 2 4 provides start Xs 3 Wire Start stop signals and a preheat signal for a three wire start system It includes a preheat timer an over Stop crank timer an overcrank reset switch an Auto 10 Timing off En on eo fT Seconds o Handcrank Stop switch and three indicator lamps The 3 Wire Start module may be equipped with a preheat timer On Off switch If used the preheat timer delays the start signal 0 Timing Preheat 60 to 60 seconds while a preheat output is energized The Preheat Timing lamp is on du
13. tery cables Otherwise disconnecting the cables can result in voltage spikes high enough to damage DC control circuits Redistribution or publication of this document by any means is strictly prohibited 1 Y lt Turn the operation selector for the generator set to Stop and disconnect the starting battery negative lead first The selector switch is located on the generator set control panel on two wire start systems and on 3 Wire Start module on three wire start systems Connect the fully charged battery negative lead last to the generator set and verify the charge condition with the hydrometer A fully charged lead acid battery will have a specific gravity of 1 260 at 77 F 25 C Connect the voltmeter directly to the battery terminals and measure the voltage Compare the voltage reading with the value shown in Table 2 3 If the voltage is above or below the recommended float voltage open the cabinet door and adjust as specified in step 5 If the voltage is correct proceed to step 7 TABLE 2 3 BATTERY FLOAT VOLTAGES Lead Acid Batteries Battery Voltage 12 13 3 24 26 6 Nickel Cadmium Batteries Float Voltage Float Voltage Charge Per Cell 1 38 to 1 45 volts Example Float charge for 10 cell battery should be 13 8 to 14 5 volts 5 Use a small screwdriver to turn the adjustment potentiometer located on charger panel counterclockwise to decrease the float voltage and c
14. 24 hour clock that can store and execute up to ten change overs a week Programming the change over clock requires set ting the time of day and selecting the change over times The change over clock must be programmed to close its normally open contacts hold the contacts closed long enough to allow the generator set to start and then open the contacts Refer to the circled numbers in Figure 5 4 when reading the following instructions To set the time of day 1 If you are performing installation and setup press the R button 9 with the tip of a ball point pen to reset all memory Do not press the R button if you are only changing the time of day 2 Press the clock button 1 3 Press the h button 3 to set the hour of the day The clock uses 24 hour military time 4 Press the m button 4 to set the minutes of the hour 5 Press the 1 7 button 5 to advance the indica tor bar over the desired day number Use the 1 to represent Sunday 6 Press the Pr button 8 to enter the time To set the change over time 1 Slide the output selector switch 16 to the cen ter position The output selector switch has three positions The Off position overrides the program and holds the contacts open The position overrides the program and holds the contacts closed The center position selects program control Power Generation 5 6 C1579 3 FIGURE 5 4 CHANGE OVER CLOCK Redistribution or publication
15. Fig ures 4 18 and 4 19 to the base and lift off the block assemblies note where spacers are used 3 pole switches the A phase block on the Normal side and the C phase block on the Emergency side have a spacer under their outer mounting tabs On 4 pole switches the A phase block on the Normal side and the neu tral block on the Emergency side have this spacer Make certain that you install new block assemblies with the spacers in their original positions e The block assemblies are not identical The A and C phase blocks and the neutral block on 4 pole switches are different than the B phase block Refer to the parts manual and the part num bers stamped on the replacement block assemblies to make certain that you install new block assemblies in their correct positions 11 Remove the round head machine screws lock washers and flat washers that secure the arc chutes Figures 4 18 and 4 19 to the block as semblies and lift out the arc chutes arc chute barriers and arc chute spacers Discard the arc chute barriers and spacers 12 Remove the allen head capscrews and lug ter minals from the block assemblies 13 Remove the hex head capscrews and flat washers that secure the cross bar assembly to the base and lift off the cross bar assembly Use care when removing the block and cross bar assembly from the base Carefully disengage the crossbar from the auxiliary switch assembly to avoid cracking th
16. Optional Auto Manual Switch The optional Auto Manual switch is used to enable or disable the automatic retransfer function This switch has two positions In the Auto position nor mal automatic retransfer is enabled In the Manual position automatic retransfer from the non pre ferred source back to the preferred source is dis abled only manual retransfer using the Preferred Source Selector switch is possible In the event of power source failure however the Power Sentry control logic will ignore the Auto Manual switch and initiate retransfer to the other source When the optional Auto Manual switch is installed the standard Source Selector Switch is replaced with a three position spring return to center switch SOURCE 2 CONNECTED LAMP SOURCE 2 AVAILABLE LAMP OPTIONAL AC VOLTMETER OPTIONAL AC AMMETER OPTIONAL FREQUENCY METER SOURCE SELECTOR SWITCH M1694 2s FIGURE 6 2 UTILITY TO UTILITY CABINET WITH OPTIONS a Power Generation Redistribution or publication of this document by any means is strictly prohibited Optional Meter Package The optional meter package includes an AC amme ter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltage of the selected power source AC Ammeter The ammeter measures the line cur rents of the load Frequency Meter This meter measures the output frequency of the selected power sour
17. U 2 1 K12 4 2 Je 4 CRIS CRI7 144004 104004 E CRI8 CRIS IN4904 IN4004 CR24 CR25 1N4004 IN4004 iL CR26 CR27 CLOCK REMOTE TEST INSTANT REXFR Y xS i z 3 3 J4 3 7SIGNAL SOURCE MOD 003 AVAIL TRANSFER 003 SCHEMATIC OF MOTHER BOARD 300 3090 UTILITY TO GENERATOR SET 8 5 EXERCISE g J8 7 J8 4 JS 2 3 WIRE START 3 J8 J7 to TO TRANSFER SWITCH SAFETY GEN SET INTERLOCK 12 26 5V0C 20 8 NE 004 IN 4004 2 SIGNAL MOD POWER 2 3 WIRE J5 5 REXFR OUT SIGNAL MOD TRANS OUT SIGNAL MOD 2 3 WIRE TRANS IN SIGNAL MOD J4 J5 COM SIGNAL M0D REXFR IN SIGNAL MOD J4 START 2 GEN SET 24 SIGNAL MOD 4 BACKUP AVAIL 4 Sewa 42 do sls RETRANSFER 003 003 J5 3 2 3 WIRE 300 3090 MODIFIED XFER INHIBIT J8 J6 2 CR30 CR29 IN 1004 CR34 CR33 COM 2 3 WIRE ES1973s Redistribution or publication of this document by any means is strictly prohibited 25 G gt lt atc oz Za 22 42 22 lt 5 in lt II or Ow ug WW 2 IO Ne cc LL cc OESS o a 20utf OOL cc 7 z oc lt tc iL ra 2 gt N oc n oc lt o o
18. residual voltage from inductive loads to decay to an acceptable level before transfer is completed The length of time that the transfer switch is in the midposition can be adjusted from 0 to 7 5 seconds or 0 to 60 seconds depending on the timer option The proper adjustment is a function of the load To set the time delay align the slot on the poten tiometer with the desired marking on the faceplate Figure 5 8 If a time delay is desired make sure that the Delay No Delay switch is in the Delay position Refer to sheets 2 and 5 of your schematic and wir ing diagram package Signal Module Option The optional Signal Module Figure 5 9 has one adjustable timer The Elevator Signal delay con trols the timing of two events It delays transfer re transfer and energizes the Elevator Transfer Signal relay during the delay period This time delay is ad justable over a range of 0 to 50 seconds A Delay No Delay switch permits bypassing the tim er delay if itis not needed The timing circuit is started by a transfer or a retran sfer signal from the time delay module on the Power Sentry mother board While the timer is timing the form C Elevator Sig nal relay is energized and the Timing lamp on the Signal Module is lit At the end of the time delay the Elevator Signal relay is de energized and the switch is allowed to transfer or retransfer There are two other relays with form C contacts on the Signal Module
19. screws lock washers and locknuts Tighten to 25 to 30 2 8 to 3 4 Nem Secure the cross bar assembly to the base with the hex head capscrews 4 lock washers 4 and flat washers 4 Tighten to 70 to 75 in los 7 9 to 8 5 Nem torque Apply a thin coat of glyptol between the arc chute spacers and the arc chute barrier Place the arc chute spacers 2 arc chute barrier and arc chute in position on each block assembly and secure with round head machine screws 2 lock washers 2 and flat washers 2 Tighten to 15 to 20 in lbs 1 7 to 2 3 Nem torque Apply a thin coat of electrical joint compound between the mating surfaces of the block as sembly and the lug terminals Install the lug ter minals on the block assemblies and secure with the allen head capscrews Tighten to 28 to 33 ft Ibs 40 0 to 44 7 Nem torque Place each block assembly in position on the base and secure with the hex head capscrews and flat washers Refer to Figures 4 18 and 4 19 to determine where the spacers are re quired Tighten the capscrews to 70 to 75 in lbs 7 9 to 8 5 Nem torque e On 3 pole switches the A phase block on the Normal side and the C phase block on the Emergency side have a spacer under their outer mounting tabs On 4 pole switches the A phase block on the Normal side and the neu tral block on the Emergency side have this spacer Make certain that you install new block assemblies with the spacers in their or
20. the timer signals for the generator set to start The purpose of this delay is to prevent gen erator set start up when power interruptions of very Power Generation 2 5 short duration occur An optional time delay mod ule with a 0 to 90 second start time delay range is also available The utility to utility transfer switch has no start time delay The transfer time delay adjustable from 0 to 120 seconds begins timing as soon as the Source 2 voltage sensor signals that power is available At the end of the delay the timer signals for the load to transfer to the generator set The purpose of the delay is to allow the generator set to stabilize before the load is applied When the Source 1 power returns and Source Available signals are received from both voltage sensors the time delay module will respond to the preferred source In utility to generator installa tions Source 1 is recognized as the preferred source In utility to utility or generator to generator installations the preferred source is selected by setting an externally mounted selector switch The retransfer time delay adjustable from 0 to 30 minutes begins timing as soon as the input signal from Source 1 voltage sensor is sent to the time delay module At the end of the delay the timer sig nals for the load to transfer to the normal source The purpose of the delay is to allow the normal pow er source to stabilize before the load is applied The stop
21. 0118 962 0125 962 0600 962 0602 962 0604 962 0611 962 0512 962 0513 Title BT Transfer Switch Manuals Numbers 962 0121 962 0607 962 0514 PURPOSE A new exerciser change over clock is available that requires new programming instructions If the exerciser change over clock in the transfer switch matches the one shown in Figure 1 of this supplement follow the programming instructions provided in this supplement This clock is referred to as an exerciser clock in manuals that cover utility to genset applications and it is called a change over clock in genset to genset applications The clock is the same for both applications Refer to the manuals provided with the transfer switch for important safety precautions and for general information on exercising or changeover Keep this copy with the transfer switch manuals for future reference FA Power 1 Redistribution or publication of this document lt i Generation by any means is strictly prohibited NEW EXERCISER CHANGE OVER CLOCK The clock is used as an exerciser clock in utility to genset applications The clock is set to start and run the generator set at programmable intervals and for selected durations In genset to genset applications the clock is used as a change over clock to initiate generator set changeover at programmable intervals When programming for a changeover the program is set only long enough to allow the genset to start As an example if the clock is pro
22. 16 to the cen ter position The output selector switch has three positions The Off position overrides the program and causes an exercise stop The position overrides the program and causes an exercise start The center position selects pro gram control 2 Press the I O button 2 An I 12 appears in the upper display window The l is a symbol for start time 3 Press the h button 3 to set the start hour 677 gt Gal Pow r 2 25 Redistribution or publication of this document Generation by any means is strictly prohibited 4 Press the m button 4 to set the start minute 5 Press the 1 7 button 5 to advance the indica tor bar 13 from 1 to 7 and back to 1 For each day to be selected for exercise press the Q button 7 when the indicator is over the de sired day number 1 represents Sunday To set the exercise stop time 1 Press the I O button 2 An O 15 appears in the lower left display window The O is a sym bol for stop time 2 Press the h button 3 to set the stop hour Press the m button 4 to set the stop minute 4 Press the 1 7 button 5 to advance the indica tor bar 14 from 1 to 7 and back to 1 For each start time selected in step 5 above there must be a corresponding stop time A program can start on day 2 pass through midnight and stop on day 3 for example but there must be a stop time for every start time Press the Q but ton 7 when the in
23. 250 260 amperes 300 400 600 amperes and 800 1000 amperes For servicing purposes each transfer switch as sembly can be separated into the following compo nents e Linear Actuator e Block and Crossbar Assembly Auxiliary Switches A separate section covers the removal and replace ment procedures for each major component within a particular range DISCONNECT AC POWER Before beginning any service procedure e f a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect all sources of AC power from the transfer switch e f there is an external battery charger discon nect it from its AC power source Then discon nect the set starting battery negative lead first The transfer switch presents a shock hazard that can cause severe per sonal injury or death unless all AC power is removed Disconnect all sources of AC power from the transfer switch before ser vicing Be sure to move the generator set operation selector switch to Stop discon nect the battery charger from its AC power source and disconnect the starting battery negative lead first Power Generation 4 1 RECONNECTING AC POWER When Finished After all service procedures are completed e f a generator is the Emergency power source connect the negative battery cable to the starting battery If applicable connect the
24. CABINET INTERIOR Power Generation Redistribution or publication of this document by any means is strictly prohibited 2 gt Power Sentry Time Delays Start Time Delay This delay is adjustable from 0 to 15 seconds or optionally 0 to 90 seconds This brief time delay prevents generator set starting dur ing power interruptions of short duration Timing starts the moment of power interruption If the dura tion of interruption exceeds the delay time the con trol system signals the other generator set to start To set this time delay align the slot on the poten tiometer with the desired marking on the Power Sentry cover Stop Time Delay This delay is adjustable from 0 to 10 minutes It begins timing when the load is re transferred to the other generator set At the end of the delay the stop signal is sent to the generator set that is no longer connected This time delay allows the generator set to cool down at no load before stopping To set this time delay align the slot on the poten tiometer with the desired marking on the Power Sentry cover Transfer Time Delay This delay begins when generator voltage and frequency reach the settings of the control After the delay the transfer switch transfers the load to the generator set This brief time delay allows the generator set to stabilize be fore the load is applied It has an adjustable range of 0 to 120 seconds To set this time delay align the slot on
25. Control OV amp O U Hz Source 1 C017 Meters Meters None D001 Meters Door Mounted D002 Program Transition Program Transition 0 7 5 Sec J021 Program Transition 0 60 Sec J022 Power Generation FEATURE FEATURE DESCRIPTION OPTION Battery Chargers Battery Charger 2A 12 24V K001 Battery Charger 10A 12V K002 Battery Charger 10A 24V K003 Auxiliary Relays Aux Relay 24 VAC Coil L001 Aux Relay Emergency Position L002 Aux Relay Normal Position L003 Aux Relay Emergency Source L004 Aux Relay Normal Source L005 Aux Relay 24 VDC Coil L101 Aux Relay Emergency Position L102 Aux Relay Normal Position L103 Aux Relay Genset Start L104 Aux Relay 12 VDC Coil L201 Aux Relay Emergency Position L202 Aux Relay Normal Position L203 Aux Relay Genset Start L204 Miscellaneous Clock 7 Day Exerciser J001 Module Signal M001 Module 3 Wire Start M002 Terminal Block 30 Points M003 Monitor Phase Seq Bal M004 Sequencer Stdby Set Start 12V M006 Load Shed From Emergency M007 Module Alarm M008 Sequencer Stdby Set Start 24V M010 Switch Auto Manual Change N001 Term Block Batt Chrg Alarms N002 Term Block Source1 2 Rmt Signal N005 Powe
26. EXERCISE SIGNAL MOD CRI6 CRI p gt E CR19 16 10 J6 9 J6 2 BACKUP SOURCE FAIL SIGNAL MOD J6 3 76 14 e C CR40 CR39 176 13 REXFER OUT SIGNAL MOD TRANSFORMER EMERGENCY TRANS OUT SIGNAL MOD TRANSFORMER NORMAL SOURCE 1 74 AVAILABLE SIGNAL MOD TRANS IN SIGNAL MOD REXFER IN SIGNAL MOD START GENSET 2 3 WIRE START GENSET 1 SIGNAL MOD SOURCE 2 AVAILABLE 2 3 WIRE SOURCE 2 AVAILABLE SIG MOD SIGNAL MODULE 2 3 WIRE REMOTE TEST lt _ 1 GND GND 24VAC 300 3953 MODIFIED AREA INDICATOR AREA B INDICATOR NOTE PARTS NOT ADDED ON THIS ASSY USED ONLY ON AREA PROTECTION ASSY SCHEMATIC OF MOTHERBOARD 300 3953 UTILITY TO GENERATOR SET OW v r 8 3 Redistribution or publication of this document eneration by any means is strictly prohibited 7 7 J8 Ka us TO SOURCE 8 TO SOURCE J8 GENSET START l J8 GENSET 2 START CONTACT 7 Oe CONTROLLED CONTROLLED 4 1 J P 4 14 LIGHT J8 9 LIGHT du ie COM NE J3 6 COM 7 2 3 wIRE 2 3 WIRE RETRANSFER bkis KIZ KI3 J 28 28 i 7 1 0 TO GND J8 TO TRANSFER 7
27. I lt o 5 lt a 2 z lt I o S 133HS 335 lt 133HS 335 S L33HS 335 gt 133HS 335 P 133 6 335 133 6 336 C 133HS 335 NO ONY Z 378971 3381056 gn33ug SJEY AUT3Y 76 9165 38018A313 351283 3 1531 Aday 3n8gIUAH 3230n0S tev HILTAS 3015 1528 Ad73H 6228 AUT3M 378971 Z 3941056 PNEU 1889156 135 9 II319 0N3931 318u8lI8AU lON 3905105 NADYA HLIM NAOHS SHn220 H3JSNUML QUO 340438 11 37 bLSNrdy N 3904 N3JSNUML S1281NO2 NOILISOd NI NAOHS 391283X3 MO 1531 9 N3JSNUNL S12UI1NOJ NOIL1ISOd UMMON NI NMOHS LON 324nOS HLIA NMOHS HWHON 01 035073 HILIAS JHL ONY 0321943N3 30 NAOHS S3JIA3Q 1198 El 21 1 gi 6 8 L 9 aso lt SALON N 7 lt on a s s rra 969 B0E 915 4 y NS IS 37180 118AU 334n0s dri33uUg V 78 915 308871 YAY 393105 V IBNSIS JSNUML M01U8A3713 y 19 915 3S1293X3 1531 V ToN9 IS 318uT1IUAU 5 LI os r P
28. If the generator set does not crank go to Step 5 With the Auto Handcrank Stop switch in the Handcrank position can the generator set be started from the generator set control There is a problem with the generator set consult the generator set service manual Place the Auto Handcrank Stop switch in the Auto position Is there a jump er from TB2 GND to TB2 2 There should NOT be a jumper from TB2 2 to 2 Install a jumper from TB2 GND to TB2 2 If generator set still does start then go to step 9 15 there approximately 12 VDC between TB3 1 located on the left side of the cabinet and ground Connect the starter battery to TB3 1 15 there B voltage 12 at TB3 4 There is an open in the wiring between TB3 and the generator set Find and repair it Is the Overcrank Lockout lamp lit 2 er pad Power 3 9 Redistribution or publication of this document Generation by any means is strictly prohibited 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 The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components Y TROUBLESHOOTING 3 6 Conti
29. Percent voltage unbalance range is 2 to 8 380 volt units Standby Set Start Sequencer The optional standby set start sequencer Figure 2 9 is available and applicable only on a genera tor set to generator set transfer switch In dual standby applications the power cables from two generator sets are connected to the source 1 and source 2 lugs of a generator set to generator set transfer switch which in turn provides power to the generator set source lugs on a utility to generator set transfer switch The function of the standby set start sequencer is to respond to a remote start signal from the utility to generator set transfer switch by directing a start sig nal from the generator set to generator set transfer switch to the RMT start input of the generator set that is selected as the preferred source The stand by set start sequencer permits normal backup set operation if the preferred active set fails The se quencer also permits normal change over clock ini tiated operation Refer to section 5 and to the system interconnection drawings if applicable 24 Generation 2 13 A Phase B Phase Phase TB2 7 amp 8 307 2801c FIGURE 2 8 PHASE SEQUENCE BALANCE MONITOR CUSTOMER CONNECTION TB T e m j O 300 3893s FIGURE 2 9 STANDBY SET START SEQUENCER OPTION Redistribution or publication of this document by any means is strictly prohibited Flo
30. Switch Assembly 1 After disconnecting all sources of AC power open the transfer switch cabinet door that each switch must be assembled so the side with two terminals faces inward Figures 4 13 4 14 and 4 15 when the auxiliary switch assembly is installed on the base Hold the auxiliary switch assembly in position on the base the side with two terminals must face inward and secure the bracket to the base with the hex head machine screws Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem 2 Loosen and remove the four machine screws that secure the plastic switch cover to the trans Install the control wiring leads on the corre fer switch and lift off the cover sponding switch terminals Leads are marked 3 Loosen and remove the four machine screws with the terminal numbers S2 NO SS NC that secure the terminal bracket Figure 4 11 S7 C etc for identification Refer to figures to the base Move the terminal bracket to allow 4 13 4 14 and 4 15 for identification of the access to the base auxiliary switch terminals 4 Remove the control wiring leads from the auxil Place the terminal bracket in position on the iary switch terminals Figure 4 15 base and secure it with the hex head machine 5 Close the transfer switch to the side you are screws Tighten to 25 to 30 in lbs 2 8 to 3 4 working on and remove the hex head machine Nem screws that secure the auxiliary switch assem Place the plastic cover in position and
31. The interlock assembly must hold one side open so that only one side closes at at time Replace the linear actuator as described in Lin ear Actuator Removal And Replacement sec Power Generation 13 tion for 40 to 125 ampere switches Follow steps 2 through 8 in the Replacing Actuator section Apply a thin coat of lubricant Onan part number 524 0157 to the slot in the handle Test the switch for proper operation and close the cabinet Redistribution or publication of this document by any means is strictly prohibited AUXILIARY SWITCH REMOVAL AND REPLACEMENT 40 to 125 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the auxiliary switch for 40 to 125 am pere switches Removing Auxiliary Switch Assembly 1 Open the transfer switch cabinet door 2 Loosen and remove the four machine screws with flat washers tha
32. When K16 is energized its run inter lock contacts K16 2 K16 4 are open preventing K11 from being re energized This prevents the control from stopping the generator set as long as it is still powering the load Normal Power Source Returns The time delay module is programmed to identify the Normal power source as the preferred power source The return of Normal power initiates sever al control responses that eventually cause the load to retransfer to the Normal side Source 1 Voltage Sensor The Source 1 voltage sensor monitors the Normal power source When the voltage and frequency satisfy the pickup setting requirements the sensor signals that Source 1 volt age is available The Source 1 Available lamp lights and stays on as long as the Normal source voltage is within the voltage and frequency settings of the voltage sensor Redistribution or publication of this document by any means is strictly prohibited Retransfer Time Delay The retransfer time delay begins timing as soon as the voltage sensor signals that Source 1 voltage is available The retransfer time delay is adjustable from 0 to 30 minutes The Retransfer Timing lamp lights while the retransfer time delay is timing This delay allows the line volt age to stabilize before retransferring to the Normal power source Retransfer of Load After the retransfer time delay has timed out the time delay module generates a retransfer signal If the optional Signal Module
33. an Redistribution or publication of this document by any means is strictly prohibited Optional Meter Package The optional meter package includes an AC amme ter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltage of the selected power source AC Ammeter The ammeter measures the line cur rents of the load Frequency Meter This meter measures the out put frequency of the selected power source in hertz Phase Selector Switch This switch is used to se lect the source and phase to be measured On transfer switches with an AC ammeter the load wires must each pass through a current transform er TRANSFER SWITCH The transfer switch Figure 5 3 opens and closes the contacts that transfer the load between source 1 and source 2 generator sets The transfer switch is mechanically interlocked to prevent simultaneous closing to both power sources The main parts of the transfer switch discussed here are the contact assemblies linear actuator Motor Disconnect switch and auxiliary contacts Contact Assemblies The automatic transfer switch has either three or four poles Three pole transfer switches are pro vided with a neutral bar The contact assemblies make and break the current flow When closed to either the source 1 or the source 2 generator set the contacts are mechanically held A mechanical interlock prevents them from closing to both g
34. any means is strictly prohibited 6 Connect the ground wire to the end of the ac tuator Use wire ties to hold the actuator lead wires in place with the rest of the wiring har ness 7 Check operation of the transfer switch and alignment of the actuator rod by manually opening and closing both the Normal and emergency switch assemblies 8 Place the plastic switch cover in position and secure with machine screws 2 flat washers 2 and self locking nuts 2 Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem torque 9 generator set is the Emergency power source connect the starting battery negative GROUND lead last If applicable connect the battery BRUSH charger to its AC power source Reconnect sc1559 the Normal power source and the Emergen cy power source Place the operation selec tor switch in the Remote position FIGURE 4 7 LINEAR ACTUATOR 150 TO 260 AMPERES 10 Test the switch for proper operation and close the cabinet FA Power 4 11 Redistribution or publication of this document d Generation by any means is strictly prohibited BLOCK AND CROSS BAR ASSEMBLY REMOVAL AND REPLACEMENT 150 to 260 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconne
35. board there is a Switch S4 S4 is the Test With Without Load selector When this switch is in the With Load position the lo cal test function using the Test switch on the cabi net door includes the transfer of load to the Emer gency side When S4 is in the Without Load posi tion the test function starts and runs the generator set but does not transfer the load The With Without Load switch es is are included only on the utility to generator set transfer switch Switches S2 and S3 are used to select single or three phase operation Redistribution or publication of this document by any means is strictly prohibited 2 Relays There are six relays the 300 3090 mother board and eight relays on the 300 3953 mother board Three are used to send primary con trol signals and the others are used to control logic functions on the mother board itself Relays K10 and K18 are included only on the 300 3953 mother board These two relays are criti cal to the operation of with load test and exercise Refer to Control System Operation The K11 two wire run relay responds to a signal from the time delay module When this normally en ergized relay is de energized K11 contacts 3 and 2 close to send a two wire start signal Note Output connections for two wire starting are made at TB2 on the transfer switch assembly There are 2 two wire start relays on the generator set to generator set mother board The K12 sou
36. can bypass the retransfer delay by moving the Test Normal Retransfer switch to the Retransfer posi tion This sends a signal to J7 12 which is optically coupled to the time delay module where it overrides the retransfer timer In response to this signal the time delay module signals K15 and retransfer oc curs without delay For Normal operation the Test Normal Transfer switch must be in the Normal position Test Exercise With Without Load Mother Board 300 3953 To follow this description of Power Sentry control of generator set test and exercise functions refer to the schematic of mother board 300 3953 in section 8 On the schematic locate switches S1 and S4 and relays K10 K11 K12 K13 K16 and K18 Lo cate the Test Normal Retransfer switch S12 on sheet 2 of the schematic and wiring diagram pack age Signal to Test Exercise The signals that initiate test or exercise enter the mother board at Local Test input J7 9 from the Test Normal Retransfer switch S12 3 S12 4 e Exerciser Clock input J7 8 or e Remote Test input J8 7 These signals consist of a switch closing to ground The Exerciser Clock and Local Test inputs each have a corresponding With Without Load switch la beled S1 and S4 respectively If a switch is in the With Load position a local test or exercise signal will energize K18 If a switch is in the Without Load Redistribution or publication of this document by any means is strictly prohi
37. change over clock Refer to section 5 if applicable cD Programming the exerciser clock requires setting the time of day and entering the exercise start and stop times This procedure is described under Ad justing Optional Control Modules 5 1579 FIGURE 2 7 EXERCISER The output of the exerciser clock is a set of normally open contacts that when closed provide a ground to the Power Sentry mother board schematic in section 8 input J7 8 This signal energizes test ex ercise relay K13 on the mother board The Exercise With Without Load switch provides the option of transferring or not transferring the load during the exercise periods The three position switch in the lower left corner of the clock can be used to override the program To test the exercise function close the output con tacts place the switch in the I position To disable the exercise function hold the output contacts in the open position place the switch in the Off posi tion For normal operation output contacts under program control place the switch in the center clock position The exerciser clock is powered by the 24 VAC out put of T1 An internal nickel cadmium battery not replaceable maintains time and program informa tion for 150 hours minimum without external pow er However the clock does not initiate exercise pe riods when it is under battery power Refer to sheets 2 and 5 of your schematic and wir ing di
38. diagram package Relays Interposing relays K1 and K2 are used to transfer line power to the linear actuator motor M1 The closing of K1 contacts causes retransfer to the Nor mal side The closing of K2 contacts causes trans fer to the Emergency side K1 is energized by the closing of K15 contacts K2 is energized by the closing of K14 contacts K15 and K14 are on the mother board Refer to sheets 2 4 and 5 of your schematic and wiring diagram package Optional programmed transition relay K3 is used to open the circuit that drives the linear actuator motor M1 for a time determined by the setting of the Pro gram Transition module Refer to sheets 2 and 5 of your schematic and wiring diagram package and to Optional Control Modules and Accessories in this section Optional load shed relay K4 not shown is driven by a customer supplied signal and is used to drive the linear actuator motor M1 from the emergency position to the neutral position Refer to sheets 1 2 and 5 of your schematic and wiring diagram pack age and to Optional Control Modules and Accesso ries ES1691 1 FIGURE 2 2 ACCESSORY CONTROL PANEL Power 2 7 Redistribution or publication of this document by any means is strictly prohibited Fo x o Generation 1 Y lt Motor Disconnect Switch 61 Motor Disconnect Switch S1 is used to disable the linear actuator motor In the Off position the switch is open In t
39. in the positions given below The gen erator set must also be set for automatic operation Refer to section 5 6 or 7 if applicable Test Normal Retransfer switch Normal position Motor Disconnect switch Auto position Operation selector switch engine control Remote position Two wire start for water cooled generator sets only Stop Auto Handcrank switch Auto position Three wire start for air cooled gen erator sets only Manual Operation The transfer switch has operator handles for manu ally transferring the load Use the following proce dure 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 If possible remove all AC power to the transfer switch before manually operating the switch If it is necessary to perform manual operation with AC power connected follow the Safety Related Work Practices listed in NFPA 70 1 Open the cabinet door of the automatic transfer switch 2 Move the Motor Disconnect switch to the Off position 3 Transfer from the Normal to the Emergen cy power source A Pull the upper manual operator handle down B Push the lower manual operator handle down Retransfer from the Emergency to the Nor mal power source C Pull the lower manual operator handle up D Push the upper manual operator handl
40. is not used the retransfer signal energizes the retran sfer control relay K15 If the Signal Module is used the retransfer signal is delayed for a preset time 0 to 50 seconds During this delay the Signal Module energizes an Elevator Signal relay to announce that a retransfer is about to occur When K15 is energized with or without the Signal Module delay its normally open contacts close and energize retransfer relay K1 When K1 is ener gized its contacts direct Normal power to the linear actuator retransferring the load back to the Normal power source Without programmed transition the linear actua tor circuit path includes K1 contacts circuit breaker CB1 Motor Disconnect switch S1 and auxiliary switch S4 Capacitor s C1 provides the phase shift necessary to drive the linear actuator If the Program Transition module is used there is a pause 0 to 60 or 0 to 7 5 seconds at the neutral position The timing of this pause is controlled by the Program Transition module The linear actuator drive circuit is controlled by and auxiliary switch S9 With programmed transition the circuit path pro vided by the normally closed contacts of K3 and auxiliary switch S9 allows the switch to move from the Emergency side to the neutral position Switch S9 then breaks the linear actuator drive circuit forcing the switch to wait for the Program Transition module to time out After the normally open K3 con tacts on
41. is bad or the transformer itself is bad Replace the transformer or repair the wiring as required If there is line voltage at the Normal lugs of the transfer switch then there is an open in the wiring from the Normal lugs Phase A and B to the primary side of T1 Find it and repair it Unplug P2 while watching K1 Does the relay drop out Either relay K1 on the accessory control panel could be defective or there could be an open in the wiring from J7 6 to K1 There may be an open between K1 9 or K1 7 and the linear motor The circuit breaker CB1 could be open or defective or the linear motor M1 could be defective CB1 and M1 are located on the transfer switch P ower 3 3 Generation Redistribution or publication of this document by any means is strictly prohibited 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 The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components TROUBLESHOOTING 3 2 Source 1 Voltage Sensor Does Not Sense Voltage Place the Test With Without Load switch in the Without Load position When taking voltage measurements be sure that the probe penetrat
42. is not sensed replace the mother board and recal ibrate the voltage sensors wer 3 4 Redistribution or publication of this document ot Y lt Generation by any means is strictly prohibited 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 The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components Improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety precautions in your generator set manuals Automatic transfer switch operation results in rapid movement of the switch mechanism and presents a hazard of severe personal injury Keep hands clear of the switch handles when switch ing to automatic operation X gt Oo 4 w TROUBLESHOOTING 3 3 Transfer Switch Does Not Transfer During a Power Failure Test or Exercise This procedure is to be performed with the generator set running and the Test switch in the Test position MAKE SURE THAT THE MOTOR DISCONNECT SWITCH IS IN THE AUTO POSITION NOTE if the Program Transition module is used and transfer switch only moves to the mid transition disconnected pos
43. itself This short delay pre vents the time delay module from responding dur ing momentary dips in voltage Power Generation The optional overvoltage sensor begins timing if the source voltage rises above the dropout setting The overvoltage dropout time delay is adjustable from 0 to 120 seconds The Source 1 Available and Re transfer Complete lamps remain on during the tim ing period If the voltage returns to normal during the timing period the sensor resets itself The optional over underfrequency sensor begins timing if the source frequency rises above or falls below the dropout setting The frequency dropout time delay is adjustable from 0 to 15 seconds Un less power is lost completely both the Source 1 Available lamp and the Retransfer Complete lamp remain on during the timing period If the frequency returns to normal during the timing period the sen sor resets itself Start Time Delay If the Normal power source is still faulty after the voltage sensor has timed out all indi cator lamps go out and the start time delay begins timing The start time delay is adjustable from 0 to 15 seconds or optionally from 0 to 90 seconds All lamps stay out while the start time delay is tim ing The start time delay prevents generator set startup when a power interruption of very short duration occurs If the Normal power source returns during the timing period the start time delay is re set Capacitor C1 on the mo
44. of this document by any means is strictly prohibited Press the I O button 2 An I 12 appears in the upper display window The l is a symbol for closing contacts Press the h button 3 to set the change over hour Press the m button 4 to set the change over minute Press the 1 7 button 5 to advance the indica tor bar 13 from 1 to 7 and back to 1 For each day to be selected for changeover press the Q button 7 when the indicator is over the de sired day number 1 represents Sunday For each contact closure time selected in steps 1 to 5 above there must be a corresponding contact opening time Program the change over clock to hold the contacts closed for five minutes Press the I O button 2 An 15 appears in the lower left display window The O is a sym bol for opening contacts Press the h button 3 to set the hour Press the m button 4 to set the minute Press the 1 7 button 5 to advance the indica tor bar 14 from 1 to 7 and back to 1 Press the Q button 7 when the indicator is under the de sired day number To enter the complete program press the Pr button 8 If all program requirements have been satisfied the display returns to the time of day If the program requirements are not met the display of the section that needs correction flashes on and off To enter more programs repeat the ten step procedure A maximum of ten pro gr
45. on engine control two wire start Remote position Manual Operation The transfer switch has operator handles for manu ally transferring the load Use the following proce dure 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 If possible remove all AC power to the transfer switch before manually operating the switch If it is necessary to perform manual operation with AC power connected follow the Safety Related Work Practices listed in NFPA 70E 1 Open the cabinet door of the automatic transfer switch 2 Move the Motor Disconnect switch to the Off position Power Generation 3 Transfer from the Normal source 1 to the Emergency source 2 power source A Pull the upper manual operator handle down B Push the lower manual operator handle down Retransfer from the Emergency source 2 to the Normal source 1 power source C Pull the lower manual operator handle up D Push the upper manual operator handle up 4 Before moving the Motor Disconnect switch back to the Auto position remember the trans fer switch will transfer load to the active power source If both power sources are available it will transfer the load to the priority source Automatic transfer switch op eration results in rapid movemen
46. opens and closes the contacts that transfer the load between Normal and Standby power The transfer switch is mechani cally interlocked to prevent simultaneous closing to both power sources The main parts of the transfer switch discussed here are the contact assemblies linear actuator Motor Disconnect switch and auxil iary contacts Contact Assemblies The automatic transfer switch has either three or four poles Three pole transfer switches are pro vided with a neutral bar The contact assemblies make and break the current flow When closed to Power Generation 7 3 either the Normal or the Standby power source the contacts are mechanically held A mechanical in terlock prevents them from closing to both power sources at the same time Linear Actuator The linear actuator is a linear induction motor that moves the contact assemblies between the Normal power source and the Standby power source Nor mally linear actuator operation is initiated electri cally Manual operation of the transfer switch is also possible Refer to Manual Operation in this section Motor Disconnect Switch The Motor Disconnect toggle switch on the acces sory control panel enables and disables the linear actuator Place the switch in the Off position for manual operation and in the Auto position for elec trical local remote operation Auxiliary Contacts Auxiliary contacts are provided on the Normal and Emergency Standby sides of t
47. power the end of the timing period the lamp goes out and the Retransfer Complete lamp turns on Retransfer Complete Control is signaling for retransfer to Source 1 power The Source 1 Available lamp is also on Transfer Timing Control is timing out for transfer to Source 2 power At the end of the timing period the lamp goes out and the Transfer Complete lamp turns on Transfer Complete Control is signaling for retransfer to Source 2 power The Source 2 Available lamp is also on Generation Power ot Y Redistribution or publication of this document by any means is strictly prohibited ACCESSORY CONTROL PANEL AND TERMINAL BLOCKS The accessory control panel Figure 2 2 includes e T1 and T2 transformers T3 optional transformer K1 and K2 interposing relays K3 and K4 optional relays Motor Disconnect Switch S1 Connectors J1 J2 and J3 TB4 terminal block Not included on the accessory control panel but re lated in function are terminal blocks TB1 TB2 and TB3 Figure 2 3 Transformers Transformers T1 and T2 provide 24 VAC power for the cabinet door display lamps relays K1 K2 and K16 and the optional exerciser clock K16 is on the mother board Refer to sheets 2 3 and 4 in your schematic and wiring diagram package Transformer is used with the optional voltage and frequency meters on units that are rated at more than 300 volts Refer to sheets 2 and 5 in your schematic and wiring
48. power source 2 Transfer the load to the Backup power source 3 Sense the return of the Preferred power source 4 Retransfer the load to the Preferred power source Gra Power 6 1 Redistribution or publication of this document oO 4 Generation by any means is strictly prohibited CABINET The standard cabinet meets the requirements of the National Electrical Manufacturers Association NEMA for a UL Type 1 cabinet This type is desig nated as a general purpose indoor cabinet Items on the door of a typical cabinet are shown in Figure 6 2 Indicator Lamps There are four indicator lamps on the cabinet door The Source 1 Available and Source 2 Available lamps are lit whenever their corresponding power sources are producing power These two lamps can be lit simultaneously The Source 1 Connected and Source 2 Connected lamps indicate which power source is connected to the load Only one of these two lamps can be lit Source Selector Switch This two position switch is used to select which source is preferred and which source is the backup SOURCE 1 CONNECTED LAMP SOURCE 1 AVAILABLE LAMP Onon Transfer Switch PHASE SELECTOR SWITCH FOR OPTIONAL METERS OPTIONAL AUTO MANUAL SWITCH In the Source 1 position the Normal power source supplies the load power until a power interruption occurs In the Source 2 position the Emergency power source supplies the load power until a power inter ruption occurs
49. prohibited 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 The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components TROUBLESHOOTING 3 3 Continued Transfer Switch Does Not Transfer During a Power Failure Test or Exercise This procedure is to be performed with the generator set running and the Test switch in the Test position 11 Place the Signal Module Delay No Delay switch back in the Delay position Go to step 12 15 there approximately 24 between J7 4 on the mother board and ground 15 there approximately 24 between J7 5 on the mother board and ground Replace the mother board and recalibrate the voltage sensors 15 there approximately 24 between T2 X1 and and T2 X2 located on the accessory control panel Either switch S7 located on transfer switch assembly is defective or there is an open in the wiring from transformer T2 X1 to J7 5 on the mother board Is there line voltage on the primary side of T2 on the accessory control pan el Either the connection at transformer T2 is bad or the transformer itself is bad Replace the transformer or repair the wir
50. 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 Move the Motor Disconnect switch to the Auto position 6 Close and lock the cabinet door TROUBLESHOOTING The following procedures describe preliminary troubleshooting checks 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 For this reason do not touch or allow clothing tools or jewelry to contact exposed electrical terminals whenever the cabinet door is open Make sure you are standing on a dry insulating surface Transfer Switch Does Not Transfer Automatically 1 Check the Motor Disconnect switch It should be in the Auto position 2 Is the Source Selector switch in the correct position 3 Has the transfer time delay expired 4 Has the programmed transition time delay if equipped expired 5 15 backup source voltage sufficient to trigger the backup source voltage sensor Transfer Switch Does Not Retransfer Automatically 1 Check the Motor Disconnect switch It should be in the Auto position 2 Is the Source Selector switch in the correct position 3 Has the retransfer time delay expired 4 Has the programmed transition time delay if equipped expired 5 Is preferred source voltage sufficient to trigger the preferred source voltage sensor Redistribu
51. secure bly bracket to the base with the hex head screws and flat washers 6 Lift out the auxiliary switch assembly Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem 7 Remove the hex head machine screws and nuts that secure the auxiliary switches to the bracket Figure 4 15 and lift out the auxiliary switches and insulating barriers Replacing Auxiliary Switch Assembly 1 Install the insulating barriers 5 and auxiliary switches 4 in the brackets and secure with hex head machine screws 2 and nuts 2 Tighten to 10 to 15 in lbs 1 1 to 1 7 Nem Note If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emergen cy power source Place the operation selec tor switch in the Remote position Test the transfer switch for proper operation and close the cabinet TORQUE TO 10 TO 15 IN LBS 1 1 TO 1 7 Nem BARRIERS SC1561 FIGURE 4 15 AUXILIARY SWITCH 300 TO 600 AMPERES Lan Pm 7 2d Powe J 4 24 Redistribution or publication of this document o Generation by any means is strictly prohibited Y lt LINEAR ACTUATOR REMOVAL AND REPLACEMENT 800 and 1000 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both
52. signal the time delay module which controls the transfer or retransfer sequence An adjustable time delay 0 to 120 seconds over rides momentary overshoots in voltage To set this time delay align the slot on the poten tiometer with the desired marking on the Power Sentry cover Overvoltage adjustment and calibration proce dures are described in section 2 Frequency Sensing With optional frequency sensing the sources are monitored for variations in frequency The sensors determine whether the source is within an adjustable bandwidth As with the standard undervoltage sensing the fre quency sensors signal the time delay module which controls the transfer or retransfer sequence An adjustable time delay 0 to 15 seconds allows the control to ignore momentary dips or rises in fre quency To set this time delay align the slot on the poten tiometer with the desired marking on the Power Sentry cover Redistribution or publication of this document by any means is strictly prohibited 1 Y lt Change over Clock Option The optional change over clock initiates generator set starting and operation at programmable inter vals When the source selector switch on the cabi net door is in the Auto position the change over clock determines which generator set has priority Programming the Change over Clock The change over clock initiates generator set changeover at programmable intervals t is a 7 day
53. the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the linear actuator for 800 and 1000 ampere switches Removing Actuator 1 Open the transfer switch cabinet door 2 Remove a hex head capscrew flat washer and lock washer that secures one of the rod end as semblies to the end of the actuator rod 3 Remove the rod end assembly Figure 4 16 and slide the actuator rod out of the actuator motor 4 Loosen and remove the twelve machine screws with flat washers that secure the three plastic switch covers to the switch base and lift off the switch covers Figure 4 16 5 Separate the actuator lead wires from the rest of the wiring harness remove the wire ties as required 6 Pry the capacitors loose from the brackets Re move the end cap and disconnect the red and white actuator lead wires from the capacitor terminals Power Generation 7 Disconnect the black actuator lead wire from the circuit breaker and the ground wire from the end of the actuator 8 Remove the hex head capscrews flat was
54. the Program Transition module close the circuit path to the linear actuator is completed and the switch is transferred to the Normal side The Retransfer Complete lamp lights and stays lit as long as the control is signaling for the load to be connected to the Normal power source Auxiliary switches S2 S3 S4 and S5 are actuated when the transfer switch is in the Normal position Switch S4 acts as a limit switch to break the circuit path to the linear actuator Switch S3 breaks the cir Power Generation cuit path to the coil of relay K1 and lights the Normal Connected lamp on the door Stop Time Delay The stop time delay begins tim ing as soon as the Retransfer Complete lamp lights The stop time delay is adjustable from 0 to 10 min utes The Stop Timing lamp lights while the stop time delay is timing This delay allows the generator set to cool down while running at no load When the stop time delay has timed out provided that K16 is de energized the time delay module energizes the two wire start relay K11 turns off the Start Gen Set lamp and if applicable sends a stop signal to the 3 Wire Start module On two wire start systems K11 contacts open re moving the generator set run signal On three wire start systems a relay in the 3 Wire Start module signals the generator set to stop After the genera tor set stops the Source 2 Available lamp goes out Test Exercise With Without Load Mother Board 300 309
55. the Standby source to be connected Under electrical control the transfer switch will con nect to a source only if voltage is present at that source The Normal Standby switch controls transfer switch position only when the Local Remote switch is in the Local position Local Remote Switch The Local Remote switch is used to enable the Nor mal Standby switch Local position or the remote control inputs at TB2 Remote position STANDBY CONNECTED LAMP STANDBY AVAILABLE LAMP OPTIONAL AC VOLTMETER OPTIONAL AC AMMETER OPTIONAL FREQUENCY METER NORMAL STANDBY SWITCH M1694 9s FIGURE 7 2 NONAUTOMATIC REMOTE CABINET WITH OPTIONS Redistribution or publication of this document by any means is strictly prohibited Power 7 2 E Generation 2 Optional Meter Package The optional meter package includes an AC amme ter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltage of the selected power source AC Ammeter The ammeter measures the line cur rents of the load Frequency Meter This meter measures the out put frequency of the selected power source in hertz Phase Selector Switch This switch is used to se lect the source and phase to be measured On transfer switches with an AC ammeter the source wires must each pass through a current transformer TRANSFER SWITCH The transfer switch Figure 7 3
56. the YES and NO columns direct you to the next appropriate step An X in the column means that the step should reveal or correct the problem In this procedure you are instructed to measure voltages at specific diodes The cathode is the end with the black band The anode is the end without the black band When taking voltage measurements be sure that the probe penetrates the conformal coating on the boards To perform the following procedures you will need to refer to the mother board schematic Section 8 and to the schematic and wiring diagram package shipped with the transfer switch TROUBLE PAGE Transfer Switch Does Not Retransfer 3 2 Source 1 Voltage Sensor Does Not Sense Voltage 3 4 Transfer Switch Does Not Transfer 3 5 Source 2 Voltage Sensor Does Not Sense Voltage 3 7 Generator Set Does Not Crank Two wire Start 3 8 Generator Set Does Not Crank Three wire Start 3 9 P x T 7 2d Powe J 3 1 Redistribution or publication of this document o Generation by any means is strictly prohibited Y lt 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 The following proced
57. the upper left corner of the display and the On mode will be indicated inside the ellipse in upper right corner of the display Figure 2 Press the set button again after the genset is running and the changeover will continue The ellipse will in dicate the OFF mode Repeat this procedure to change back to the original genset Redistribution or publication of this document by any means is strictly prohibited Permanent On Off Mode Note this feature is not used for any current applica tions It is described here to help recognize and get out of this mode Holding the set button down until a flashing hand appears in the upper left corner of the display initiates the permanent On Off mode Figure 2 y s Power A Generation im The On mode is indicated by a continuous band of segments illuminated around the clock The Off mode is indicated by all of the segments around the clock being off Pressing the set B button momen tarily toggles between the permanent On and per manent Off modes Holding the set B button down until the clock symbol returns to the upper left cor ner of the display ends the continuous On Off mode and returns to the normal program mode Redistribution or publication of this document by any means is strictly prohibited Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS iii 1 INTRODUCTION voe Ei ha ERAS e ming Su
58. time delay adjustable from 0 to 10 min utes begins timing as soon as the retransfer timer signals for the load to transfer to the normal source At the end of the delay the timer signals for the gen erator set to stop The purpose of the delay is to al low the generator set to cool while running at no load On the utility to utility transfer switch stop time delay is not applicable Refer to Adjusting Power Sentry Modules in this section for the time delay adjustment procedures Redistribution or publication of this document by any means is strictly prohibited Indicator Lamps Eight indicator lamps are mounted at the edges of the voltage sensor and time delay modules and are visible through holes in the Power Sentry cover Refer to Table 2 1 TABLE 2 1 POWER SENTRY CONTROL INDICATOR LAMPS INDICATES Source 1 Available Source 1 voltage is available and within the voltage and frequency settings of the voltage frequency sensor Source 2 Available Source 2 voltage is available and within the voltage and frequency settings of the voltage frequency sensor The control is signaling the generator set to run This lamp is dimly lit or off when both sources are off Stop Timing The control is timing out the generator stop delay At the end of this delay a stop signal is sent to the generator set and the Start Gen Set and Stop Timing lamps go out Retransfer Timing Control is timing out for retransfer to Source 1
59. trans fer switch The standby set start sequencer re sponds to a remote start signal from the utility to generator set transfer switch by directing a start sig nal from the generator set to generator set transfer switch to the RMT start input of the generator set that is selected as the preferred source Refer to Section 2 and to Section 5 if applicable Area Protection Remote Test Transfer The transfer switch can be wired with a remote test transfer switch Closure of a set of contacts across the remote test transfer inputs terminals 7 and 8 of TB2 causes the transfer switch to sense a simu lated utility power failure and send a start run sig nal to the generator set The load is transferred to the generator set when generator set power be comes available On 300 3090 mother boards the With Without Load switch must be in the With Load position On 300 3953 mother boards this input is NOT depen dent upon the position of With Without Load switch Transfer Inhibit Removal of the jumper across terminals 5 and 6 of TB2 prevents the transfer switch from operating This jumper may be removed when the transfer switch is used in a paralleling system If applicable refer to the interconnection drawings that are fur nished with paralleling switchgear Power Generation 1 7 OPERATION Automatic Operation The utility to generator set automatic transfer switch is set for automatic operation by placing con trol switches
60. when working on any electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling any electrical equipment Jewelry is a good conductor of electricity and should be removed when working on the electrical equipment 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 Redistribution or publicQibS MGr3 document by any means is strictly prohibited Power iv Redistribution or publication of this document by any means is strictly prohibited 1 Introduction ABOUT THIS MANUAL This manual contains service procedures for an OT transfer switch Sections 1 2 3 and 4 cover the utility to generator set automatic transfer switch Although much of the information on theory of op eration Power Sentry calibration and trouble shooting in sections 1 2 and 3 is applicable to gen erator set to generator set utility to utility and non automatic remote configurations there are several significant differences Refer to section 5 for an overview of the generator set to generator set transfer switch Refer to section 6 for an overview of the utility to utility transfer switch Refer to section 7 for an overview of the nonauto matic remote transfer switch Refer to the schematic and wiring diagram package that was shipped with the transfer switch for specific EMERGE
61. 0 To follow this description of Power Sentry control of generator set test and exercise functions refer to the schematic of mother board 300 3090 in section 8 On the schematic locate switch S1 and relays K11 K12 K13 and K16 Locate the Test Normal Retransfer switch 512 on sheet 2 of the schematic and wiring diagram package Signal to Test Exercise The signals that initiate test or exercise enter the mother board at Local Test input J7 9 from the Test Normal Retransfer switch S12 3 S12 4 Optional Exerciser Clock input J7 8 or e Remote Test input J8 7 The signal consists of a switch closing to ground A ground at K13 8 energizes K13 the test exercise relay Starting the Generator Set When K13 is ener gized its normally closed contacts open When contacts K13 2 K13 3 open K11 the normally en ergized two wire start relay is de energized and a start signal if applicable is sent to the 3 Wire Start module When contacts K13 6 K13 7 open one of three paths to the phase A B Normal side bridge rectifier at CR16 CR17 is opened Redistribution or publication of this document by any means is strictly prohibited Generator Set Starts As the generator set runs and produces power at an acceptable voltage and frequency the Source 2 Available lamp lights and the source 2 available relay K12 is energized When contacts K12 2 K12 4 open the second of three paths to the phase A B Normal side bridge re
62. 10 amperes at 12 or 24 VDC The other battery charger is rated for 2 amperes at 12 or 24 VDC The 2 ampere battery charger has an ammeter to indicate charging current and a fuse to protect the battery charger circuit The 10 ampere battery charger has three fuses two on the AC input and one on the DC output three fault display LEDs and an ammeter for indica tion of charging current On the 10 ampere charger three sets of form C alarm contacts corresponding to the three fault LEDs are also available These contacts can be wired by the installer to 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 The alarm contacts are rated for 4 amperes at 120 VAC or 30 VDC Connections to these contacts are made at terminals 41 42 43 AC failure 44 45 46 high battery voltage and 47 48 49 low battery voltage of TB3 Figure 5 11 Refer to sheet 2 of the schematic and wiring dia gram package The high and low alarm and float voltage adjust ments are set at the factory Adjustment proce dures are described in section 2 Power Generation 5 11 a lt X t lt WAL e e DC AMPERES
63. 10N 340439 SUV T SLIYLNOI 035070 X TR 201 33 83 V3 ooo TWNOTLdO Su3l3NW T P81 vi Yd PI IP 8i i Sr Td 67 1 XH zi ox o L1NVISNI t I ag NAY UB4SNVUL 2 ON gana 8 9 Obed TIC TP 8d ON ys n L 4 Ferr 7 ON x 9 6 6 27 79 ON gs Ed Z TS TW 789 19 NOTLdO NOILISNVHl HLIM L SNIUIM 31VNH3lV E 133HS 33S SW 275 ON N VN e uo Hi s i i8 Bos N lt o AHVIN3WOW 035070 X 626 1762 SHEET 2 OF 5 y prohibited Redistribution or publication of this document by any means is strict 8 7 ation ntc N 2 eo lt on 99Z1 929 335 3sUHd E 2UA 009 904 85641 969 335 3SUHd I IBA ZI N04 5 SHEET SCHEMATIC AND WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR FOR TROUBLESHOOTING REFER TO THE TRANSFER SWITCH o tc z gt LE lt o tc n lt o o SCHEMATIC WIRING DIAGRAM SS9B STE Hd p ZH H TH ZH H tH OTP 83 93 gN UN 0 SS98 STE ON YSWYOISNY
64. 2 and 36 37 and 38 unit 1 are for connection to the overcrank alarm contacts See Figure 5 7 These form C contacts are rated for 4 amperes at 125 VAC or 3 amperes at 30 VDC and are provided for customer use terminals 7 9 and 10 unit 2 and 37 39 and 40 unit 1 are for connection to the generator run ning contacts Terminals 7 and 37 are common to both overcrank alarm and generator running relay contacts See Figure 5 7 These form C contacts are rated for 4 amperes at 125 VAC or 3 amperes at 30 VDC and are provided for customer use Refer to sheet 1 of the schematic and wiring diagram package that was shipped with the transfer switch Stop Handcrank Power Generation 5 9 SOURCE 2 GENERATOR SET TERMINALS j OVERCRANK ALARM CONTACTS GENERATOR RUNNING CONTACTS SOURCE 1 GENERATOR SET TERMINALS j OVERCRANK ALARM 77 CONTACTS GENERATOR RUNNING CONTACTS jojojo L L L IL SC 1578 2 FIGURE 5 7 THREE WIRE START CONNECTIONS Redistribution or publication of this document by any means is strictly prohibited Oo 4 Programmed Transition Option The optional Program Transition module Figure 5 8 is used to introduce a pause during transition Programmed transition allows the transfer switch to assume a mid transition position for an adjustable interval of time In this position the load is not con nected to either power source This feature allows
65. 3 FIGURE 2 5 PROGRAM TRANSITION MODULE Redistribution or publication of this document by any means is strictly prohibited Y lt Signal Module The optional Signal Module Figure 2 6 has one adjustable timer The Elevator Signal delay con trols the timing of two events It delays transfer re transfer and energizes the Elevator Transfer Signal relay during the delay period This time delay is ad justable over a range of 0 to 50 seconds A Delay No Delay switch permits bypassing the tim er delay if it is not needed The timing circuit is started by a transfer or a retran sfer signal from the time delay module on the Power Sentry mother board If the transfer switch includes the Signal Module re sistors R10 and R11 on the mother board schemat ic in section 8 are removed Because these resis tors are removed the transfer and retransfer sig nals from the time delay module do not have a direct path to relays K14 and K15 Instead these signals are directed to the Signal Module and are returned to drive the relays after the elevator time delay has elapsed While the timer is timing the form C Elevator Sig nal relay is energized and the Timing lamp on the Signal Module is lit At the end of the time delay the Elevator Signal relay is de energized and the switch is allowed to transfer When installed on a utility to generator set transfer switch there are four other Signal Module relays with form C
66. 30 SNIMIM 3803 SAUT3M AMBITIXNY Jb O31181SNI ANO12U4 JO S9NIMIA 803 SAU134 AUUTTIXQU 310008 3938H 1331188 01 H3JSNUNl 2 21 dl OL Q311801SNI SI NOILJO NOILISNUMI ININIM F I 2N393343 J l 01 Sr Vm 13 841 OL 4 I 45 IY l 2118W01nH I 32038 01 535070 St te aae 17 18 OL W3MIl NOILISNEML l I I 1 re l T 1 15 vZ gt 9 n 1 TYWYN D l HILIAS 40123135 N335NUJ13M TWANUW OLNY 9441 979 3101004 NOILISNUMI 0 ELLT1 929 a B a o z 626 1762 SHEET 3 OF 5 Redistribution or publication of this document 3 any means is strictly prohibited y b 8 8 Po wer ineration e CT REAR VIEW OF DOOR THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM 052 051 FOR TROUBLESHOOTING REFER TO THE Je s h R ER 9 7 14 1 POWER SENTRY CONTROL 14 051 1 5 5 SCHEMATIC AND WIRING DIAGRAM oput PACKAGE THAT WAS INCLUDED WITH YOUR 054 053 ES TRANSFER SWITCH T2 x1 f a 2 2 nii 1 054 2 Sica SEE SHEET 3 FOR 23 4 INSTALLATION OF JUMPERS REAR WALL OF CABINET ON 11 33 9 J3 1 T811 J3 3 12 5 9 fafa J3 2 TRRNSFER SWITCH NA NB
67. 5 seconds Stop 0 to 10 minutes Transfer 0 to 120 seconds Retransfer 0 to 30 minutes An optional time delay module has an adjustable start delay range of 0 to 90 seconds To set the time delays align the slots on the poten tiometers with the desired markings on the Power Sentry cover Figure 2 14 Automatic transfer switch opera tion results in rapid movement of the manual operator handles and presents a hazard of se vere personal injury Keep hands clear of han dles when switching back to automatic opera tion If there are no optional control modules to adjust place the Motor Disconnect Switch in the Auto posi tion and close the cabinet door Power Generation 2 24 ADJUSTING OPTIONAL CONTROL MODULES AND ACCESSORIES 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 when the cabinet door is open The transfer switch can be equipped with one or more optional control modules The 3 Wire Start Program Transition and Signal modules have ad justable time delays that must be set The exercise clock must be programmed Disable the Linear Motor Accidental actuation of the linear motor can cause severe personal injury Dis able the motor as described below before mak ing adjustments Place the Motor Disconnect Switch on the acces sory control panel in the Off pos
68. AGE ai MODULE SENSOR MODULE PHASE SELECTOR I SWITCH S2 E 11 M SELECTOR SWITCH S3 TRANSFORMER ASSEMBLY ES1698 2c The schematic of the 300 3953 mother board is on page 8 3 The schematic of the 300 3267 mother board is on page 8 4 The schematic of the 300 3090 mother board is on page 8 5 Overvoage Frequency Undervoltaga DN CERCA Overvoltage Frequency Undarven CONTROL ES1690 COVER FIGURE 2 1 POWER SENTRY CONTROL Po wer 2 2 Redistribution or publication of this document Generation by any means is strictly prohibited 2 gt Mother Board Circuitry The mother board circuit ry serves several functions that are essential for control operation A series of rectifier bridges receive the AC output from the transformer assembly connector J6 and rectify it The rectified voltage 15 to 25 is used as a reference input for the voltage sensors and as a power source for the control electronics The circuitry for the rectifier bridges is shown in the schematics in Section 8 Separate voltage regulator circuits receive the out put from the Normal and Emergency side rectifier bridges and regulate the voltages to a constant val ue 12 0 5 These circuits provide power for the control relays display lamps voltage sensor modules and time delay module Capacitor C1 is large eno
69. AR ASSEMBLY INTERLOCK BAR NEUTRAL o S6 57 S8 S9 52 S3 54 55 JUMPER BUS BAR BLOCK ASSEMBLY ARC CHUTE BARRIER ARC CHUTE SPACER LOAD BUS JUMPER SPACER BAR BUS BAR D TORQUE TO 15 TO 20 IN LBS 1 7 TO 2 3 Nem 2 TORQUE TO 28 TO 33 FT LBS 40 0 TO 44 7 Nem 2 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem 5 TORQUE TO 18 TO 20 FT LBS 24 4 TO 27 1 Nem 8 TORQUE TO 70 TO 75 IN LBS 7 9 TO 8 5 Nem 8 TORQUE TO 10 TO 12 FT LBS 13 6 TO 16 3 Nem SC1568s FIGURE 4 19 4 POLE SWITCH ASSEMBLY 800 1000 AMPERES Po 7 d 4 30 Redistribution publication of this document weneration by any means is strictly prohibited Replacing the Block and Cross bar Assembly Normal or Emergency Install the interlock arm on the cross bar as sembly and secure with the round head ma chine screws Tighten the screws to 15 to 20 in Ibs 1 7 to 2 3 Nem torque Apply a thin coat of lubricant Onan part num ber 524 0157 to the slot in the handle Place the handle assembly in position on the switch assembly and secure with the shoulder
70. Caution This document contains mixed page sizes 8 5 x 11 or 11 x 17 which may affect printing Please adjust your printer settings c Poweraccording to the size of each page you wish to print on or publication of this document Generation by any means is strictly prohibited Power Generation Service Manual OT IIl Transfer Switch 40 to 1000 Amperes 962 0512 6 2001 Begin Spec G Printed in U S A Redistributic or publicatio of this document bv any meane tric tly pn rohibited Y lt Supplement 962 1026 Date 3 94 Insert with Title OT Ill Transfer Switch manuals Number 962 0512 962 0113 962 0600 PURPOSE This supplement covers III transfer switches that are intended for use in fire pump controller applications in accordance with NFPA 20 This supplement also covers the required phase sequence monitor OT Ill Transfer Switches In Fire Pump Circuit Applications Figure 1 illustrates the typical fire pump controller transfer switch arrangement Required Transfer Switch Features 1 An OT III with a standard Power Sentry control one ATS per fire pump 2 Programmed Transition module 3 Phase Sequence monitor see page 3 4 Momentary Test switch on cabinet door UL Type 3R 4 or 12 cabinet Sizing In accordance with NFPA 20 the transfer switch must be rated for at least 11596 of the pump motor full load amperes FLA Use the motor nameplate FLA if available A
71. F ee ee Fr EI s P sd e e a e 960 00 37 00 14615 3HI excu JSNUMI e avec ec ne dc cns caeci QZJ eese I pps ec ecc Oe Go SNOIL23NNOO 3WOlLS2 S3MIM 123NNO2 LON 00 NOILdO SIHL SNISN 1 SHL SI NIWYJL 33171 OL 123NNO2 2 AMIN3S YINDA 1531 1531 HNI lIGIHNI foam XBW TWA MO JOA BE 18 SdWU f 1031494 51961 09 SLLT S79 SAO NOIIUTTHISNI JINGOW ENSIS 19 01140 1281N02 Weed JNHN23AO 21 081 01 2 261 wy MO E Z T 281 OL YOLYYSN3D 3NISN3 A NO 70MINO2 HLTA S13SN39 037003 MIU N04 LLTI 978 NOIIUTTTHISNI 7031N02 SHIM 333H1 19301140 1631 01 35075 1281109 N3dO ATTHWHON B LISNNOD 11331 U3MU NO 9311531 3410834 03 351 1519 N03 STOMLNOD ALTYOI Yd SNII23NNOJ ANNO SW31SAS 9 13 304 SNIMIA 1238803 304 NOIL23NNOON3INI 31545 x Ol 3834338 SH31SAS SNIT317UMUd NO MO73 1140 3MIA 334Hl 33S JONLNOD 3HIA S13S 037005 MIU 1432X3 135N39 ANS NO STUNIWH3L 331 01 3UIA TOJINOJ MOIUH3N39 3NISN3 OL HILIAS QUA 62 O
72. ML Arye CL aa Ll Hd tH ZH 1H ZH DUA 08 M 83 8N UN ATENW3SSH YIWYOJSNYYL 33 83 U3 JN gN UN 559 5 ON 5 tH ZH ZH JUA LYE SS 93 8N UN 93 JN ON UN ZO SS9B STE ON 3HN0JSNUHL aaa 21 Oa 11 Hd 7 7 TH ZH H H JBA 08t 83 gN UN YIWYOISNYYL 6 2 658 616 YIWYOJSNYYL ZL TYYrYYTYA L Hd E TH ZH TH ZH JUA pz 83 8N UN 5590 616 ON ZH H rH tH ZH EH vH 882 93 aN UN Tt YIWYOJSNYNL rrrvyrrrrreny Il t IH TH ZH tH JUA 0 2 la gigi EN SS3NMUH 3MIA SHL OINI 3298 S3MIM 3S3Hi BIL 23 O33888 S3MIM S9n1 3A0W3H 3SUHd INA rH _ 93 3981104 SNOILJ3NNOO M3W30 ASNUYL 3NI101 WNIT 20 amp Z241 929 30 21 1221 979 9NIMUMO Ol AMBITIXNY 20 037 1815NI 4801284 JO S9NIMIA 903 9111 929 OL 833438 H ZL1 9Z9 SNIMDMO Ol AM311U8 0377615 A801384
73. MOTOR CAPSCREW WITH LOCK WASHER 9 10 11 Check the operation of the transfer switch and the alignment of the actuator rod by manually opening and closing both the Normal and Emergency switch assemblies If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emergen cy power source Place the operation selec tor switch in the Remote position Test the switch for proper operation and close the cabinet ACTUATOR ROD GROUND BRUSH SC1474s FIGURE 4 17 LINEAR ACTUATOR 800 1000 AMPERES Power Generation 4 27 Redistribution or publication of this document by any means is strictly prohibited 1 Y lt BLOCK AND CROSS BAR ASSEMBLY REMOVAL AND REPLACEMENT 800 and 1000 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfe
74. NCY SC1101 information about its configuration FIGURE 1 1 LOAD TRANSFER SWITCH Section 4 of this manual covers transfer switch as TYPICAL FUNCTION sembly service procedures for all configurations Use normal and necessary safety precautions be fore starting any service procedures Identify all hazards by referring to the Safety Precautions and observe all warnings and cautions within the manu al Whenever troubleshooting remember that the generator set transfer switch and utility power source are all interdependent TRANSFER SWITCH APPLICATION Transfer switches are an essential part of a build ing s standby or emergency power system The Normal power source commonly the utility line is backed up by an Emergency power source often a generator set The transfer switch supplies the electrical load with power from one of these two power sources The load is connected to the common of the transfer switch Figure 1 1 Under normal conditions the load is supplied with power from the Normal source as illustrated If the Normal power source is inter rupted the load is transferred to the Emergency power source When Normal power returns the load is retransferred to the Normal power source The transfer and retransfer of the load are the two most basic functions of a transfer switch Power Sentry is a registered trademark of Cummins Inc NORMAL m gt Gal Pow er 1 1 Redistribution or publication of this
75. NTROL PLATE 7 CUSTOMER MUST MOUNT AND WIRE LAMPS SWITCHES SHIPPED LOOSE SOURCE 1 POSITION SOURCE 2 POSITION SOURCE 1 AVAILABLE SOURCE 2 AVAILABLE SOURCE 1 AUTO SOURCE 2 SWITCH CONNECT TO GENSET 1 BATTERY CONNECT TO GENSET 2 BATTERY DS1 X CLOSED Redistribution or publication of this document by any means is strictly prohibited Fd lt Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 6266 763 574 5000 International Use Fax 763 528 7229 Cummins is a registered trademark of Cummins Inc Power Generation Power Generation Redistribution or publication of this document by any means is strictly prohibited
76. Normal Retransfer switch to the Retransfer posi tion The closing of contacts 512 1 512 2 sends signal to J7 12 which is optically coupled to the time delay module where it overrides the retransfer timer In response to this signal the time delay mod ule signals K15 and retransfer occurs without delay For Normal operation the Test Normal Transfer switch must be in the Normal position Redistribution or publication of this document by any means is strictly prohibited ADJUSTING POWER SENTRY MODULES AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause serious personal injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door is open Incorrect setting of the calibration Cal adjustments will result in abnormal opera tion of the transfer switch All adjustments to the sensor modules are made by turning potentiometers with a screwdriver Access to the potentiometers is made through openings in the cover of the Power Sentry control Figure 2 14 A separate voltage sensor is used for each power source They are located one on each side of the time delay module The Source 1 sensor monitors the Normal utility power source The Source 2 sensor monitors the Emergency generator set power source Disable the Linear Motor Accidental actuation of the linear motor can cause severe personal injury Dis able the motor as descri
77. Normal Standby switch to the Stand by position and hold it there until the Standby Connected lamp is lit To transfer the load to the Normal source 1 Check that the Normal Available lamp is lit The transfer switch will only permit transfer to the Normal source if the Normal source voltage is available 2 Move the Normal Standby switch to the Nor mal position and hold it there until the Normal Connected lamp is lit Remote Operation Transfer switch operation results in rapid movement of the manual operator han dles and presents a hazard of severe personal injury Keep the cabinet door closed during re mote operation To set the transfer switch for remote operation 1 Place the Local Remote switch in the Remote position 2 Place the Motor Disconnect switch on the Ac cessory Control Panel in the Auto position 3 Close and lock the cabinet door Remotely controlled transfer to the Standby source is accomplished by closing a set of normally open contacts that are connected across terminals 1 and 3 of TB2 The contacts must be held closed until transfer is complete Remotely controlled retransfer to the Normal source is accomplished by closing a set of normally Power Generation 7 7 open contacts that are connected across terminals 1 and 2 of TB2 The contacts must be held closed until transfer is complete As with local operation the transfer switch permits transfer and retransfer only when the selected sour
78. OAD SWITCHES bilize before the load is applied It has an adjustable range of 0 to 120 seconds Retransfer Time Delay This delay begins the mo ment Normal line voltage and frequency return Af ter the delay the transfer switch can retransfer the load to the Normal source The delay allows the Normal source to stabilize before retransfer It has an adjustable range of 0 to 30 minutes POWER SENTRY CONTROL AUTOMATIC TRANSFER SWITCH OPTIONAL BATTERY CHARGER SC1581 FIGURE 1 3 UTILITY TO GENERATOR SET TRANSFER SWITCH INTERIOR COMPONENTS 24 Power 1 5 os Generation Redistribution or publication of this document by any means is strictly prohibited Undervoltage Sensing Two voltage sensors one for the Normal side and one for the Emergency side monitor source volt ages for an undervoltage condition and generate signals which are sent to the time delay module If for example an undervoltage condition is sensed on the Normal source the voltage sensor module sends a signal to the time delay module that initiates and controls the timing for generator set start and the transfer of load The standard transfer switch has undervoltage sensing for all phases of the Normal and Emergen Cy power sources Overvoltage and Frequency Sensing Option Overvoltage and frequency sensing are available as a single option Overvoltage Sensing With optional overvoltage sensing the Normal and Emergency sources are monit
79. QUE TO 70 TO 75 IN LBS 7 9 TO 8 5 Nem 2 TORQUE TO 10 TO 12 FT LBS 13 6 TO 16 3 Nem 8 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem FIGURE 4 14 4 POLE SWITCH ASSEMBLY 300 TO 600 AMPERES SC1564s Dp x 1 L L 4 22 Redistribution or publication of this document Generation by any means is strictly prohibited Replacing the Block and Cross bar Assembly Normal or Emergency 1 Install the interlock arm on the block assembly using the capscrew and lock washer Figures 4 13 and 4 14 Torque to 70 to 75 in Ibs 7 9 to 8 5 Nem On 4 pole switches Figure 4 13 Secure the block and contact assembly to the base us ing the four screws removed in step 10 above Tighten the screws to 25 to 30 in lbs 2 8 to 3 4 Nem Place the bearing bracket removed in step 9 in position on the end of the cross bar assembly Install the block and cross bar assembly on the transfer switch base with the screws lock washers and flat washers carefully engaging the auxiliary switches Tighten to 70 to 75 in lbs 7 9 to 8 5 Nem On 4 pole switches tighten the bearing bracket screw to 25 to 30 in Ibs 2 8 to 3 4 Nem Clean the current carrying surfaces of the block assembly and the lug terminals with a wire brush Install the lug terminals with the round head screws and lock washers Tighten to 70 to 75 in lbs 7 9 to 8 5 Nem Secure the jumper bus bars to the block as sembly with the capscre
80. S SYMBOL PROGRAMMING MODE FIGURE 1 EXERCISER CHANGEOVER CLOCK 2 Press the arrow button once to set the day of week The clock symbol will begin flashing to indicate the clock is being programmed and the display will show midnight 0 00 3 Press the plus button as many times as nec essary until the current day of week is dis played Example 1 Monday 2 Tuesday etc 4 Press the arrow button again to set the hour of the day The clock uses 24 hour mili tary time 5 Press the plus button until the current hour is displayed Example 2 00 PM is 14 00 6 Press the arrow button again to set the minutes 7 Press the plus button until the current min utes are displayed Note that by holding the plus button down the minutes will increment in 5 minute intervals 8 To set or change the exerciser change over program press the arrow button again and go to step two in the following section To return to the normal operating mode press the arrow button eight times clock symbol appears in the display Redistribution or publication of this document by any means is strictly prohibited To Set The Exerciser Start and Stop Time 1 Press the arrow button four times to start the programming mode SEGMENTS INDICATE 2 The letters Pr will appear in the lower right hand UU OFF MODE corner of the display when the prog
81. TRANSFER CONTACT SWITCH SAFETY 1 SWITCH SAFETY INTERLOCK 1 INTERLOCK 300 3267 MODIFIED 20 30VDC l2 0 5VDC CR Il UI CRS CR28 1220 5VDC Ue 20 30VDC CR8 A 2 H mC mel we OA z c o 465 c n GA OA CRI6 CRI7 IPH 3PH A SwITCH J6 IN4004 IN4004 12 18 19 I0 l 0vDC CR20 CR 29 IN4004 144004 IN4004 IN4004 jm ii 2 POWER SIGNAL MOD CR34 CR33 B 2 3 WIRE SET us A J5 2 POWER 2 gt IN4004 J6 2 3 WIRE SET 2 ES IN4004 IN4004 _ JE S Che 2 8 6 1N4004 184004 4 FAILED SI MOD EE JG REXFR OUT CR36 CR35 5 m 5 SIGNAL MOD CR 23 IN4004 li 3 IN4004 1 4004 ue CR26 CR27 J6 IN4004 IN4004 IN4004 IN4004 amp TRANS OUT CR40 CR39 SIGNAL MOD J6 13 Sr ZS a J4 TRANS IN SIGNAL JS COM 24 2 3 WIRE SET 2 9 REXFR IN SIGNAL MOD 24 j COM SIGNAL MOD 2 3 WIRE SET 11 START SET I 2 3 WIRE SOURCE zu SOURCE OK SOURCE 2003 TRANSFER RETRANSFER m SIGNAL MOD 2 3 WIRE SET SOURCE 2 2 3 WIRE SET 2 SCHEMATIC OF MOTHER BOARD 300 3267 UTILITY TO UTILITY Power 8 4 Redistribution or publication of this document Generation by any means is strict prohibited J7 5 TRANSF ER ha CONTACT J7 47 fF J8 gol JB RETRANSFER bkis CONTACT J7 sF J7 KIG 48 L 14 TEST EXERCISE W O LOAD SW Si 20 30VDC 12 0 5vDC CRI
82. a tor rod Figure 4 2 and slide the rod out of the actuator Replacing Actuator Y lt 1 Insert the actuator rod into the replacement ac tuator motor from the side opposite the ground brush Figure 4 2 Install the rod end assembly and tighten the capscrew to 70 to 75 in lbs 7 9 to 8 5 Nem Position the actuator motor on the block as semblies so the load wires are at the bottom and fit the rod assembly into the handle of the closed switch assembly Secure the actuator motor to the block assem blies using socket head capscrews 4 and lock washers 4 Be sure to reconnect the ground wire to the lower left screw Figure 4 1 Tight en capscrews to 25 to 30 in lbs 2 8 to 3 4 Nem torque ACTUATOR CAUTION Do not overtighten screws or the switch can be damaged Connect the black actuator lead wire to the cir cuit breaker and connect the red and white ac tuator lead wires to the following capacitor ter minals Red Lead Wire Connect to capacitor C1 Ter minal 1 White Lead Wire If one capacitor connect to capacitor C1 Terminal 2 If two capacitors connect to capacitor C2 Terminal 2 Transfer switches for voltage ranges 347 380 416 440 480 and 480 use two capacitors C1 and C2 wired together in series A single jump er wire is placed between terminal 2 on C1 and Terminal 1 on C2 Replace the capacitor end cap s and install the capacitor s in the bracket s Use wire
83. agram package AG Pm gt GA Pow er 2 12 Redistribution or publication of this document o 4 Generation by any means is strictly prohibited lt Phase Sequence Balance Monitor The optional phase sequence balance monitor Figure 2 8 is connected to A B and C phases of utility power If there is an over or undervoltage a phase reversal a loss of one phase or an unbal anced voltage condition a normally energized relay drops out closing a set of contacts These relay contacts are wired to the remote test input terminals 7 and 8 of TB2 When the contacts across termi nals 7 and 8 of TB2 close the generator set start transfer of load sequence is initiated Five LEDs indicate normal operation or fault condi tions The Relay Energized LED is lit during normal operation Three potentiometers permit setting the percent of voltage unbalance the normal system voltage and the relay dropout time delay The relay dropout delay applies only to over under voltage and voltage unbalance In the event that a phase reversal or loss of one phase is sensed relay dropout occurs within 100 milliseconds maximum There is NO relay dropout delay when a phase rever sal or loss of phase is sensed Overvoltage dropout occurs at normal voltage 10 42 Undervoltage dropout occurs at normal volt age 1096 2 Dropout time delay range is 2 to 20 seconds e Percent voltage unbalance range is 2 to 6 on 240 and 480 volt units e
84. allows the switch to move from the Normal side to the neutral position Switch S5 then breaks the linear actuator drive circuit forc ing the switch to wait for the Program Transition module to time out After the normally open K3 con tacts on the Program Transition module close the Power Generation circuit path to the linear actuator is completed and the switch is transferred to the Emergency side The Transfer Complete lamp lights and stays on as long as the control is signaling for the load to be con nected to the Emergency power source Auxiliary switches S6 S7 S8 and S9 are actuated when the transfer switch is in the Emergency posi tion Switch S8 acts as a limit switch to break the circuit path to the linear actuator Switch S7 breaks the circuit path to the coil of relay K2 and lights the Emergency Connected lamp on the door Emergency Power Source Connected to Load The Source 2 Available lamp is on to indicate that the Emergency power source is within the voltage and frequency settings of the voltage sensor The Transfer Complete lamp is on to indicate that the control is signaling for the load to be connected to Emergency power source The Start Gen Set lamp is on to indicate that the control is signaling for the generator set to run When the transfer switch is in the Emergency posi and the Emergency source is energized K16 is energized by the action of position sensing auxil iary switch S7
85. ame time Double check the program setting for each day Press the arrow button repeatedly until the clock mode is passed and the pro gram mode Pr is reached Carefully check each days program and clear any unwanted programs 5 When finished programming press the arrow 7 button until the clock appears in the upper left corner of the display During the exercise period the ON mode is indi cated in the ellipse in the upper right corner of the FIGURE 2 CLOCK ON OFF MODE display Figure 2 28 Powe r 3 Redistribution or publication of this document e Generation by any means is strictly prohibited Y lt To Set The Change Over Time 1 Press the arrow button four times to start the programming mode The letters Pr will appear in the lower right hand corner of the display when the programing mode is reached Pr will be flashing if there are no existing programs Press the arrow button as many times as necessary to advance to the day to be pro grammed To clear an existing program for the day se lected press the plus and set buttons at the same time Press the plus button to increment the Start time of the change over program The display will show midnight 0 00 When the Start time is reached press the set button On Mode is indicated Figure 2 Then increment the time with the plus but ton to the desired Stop ti
86. ams can be entered The word Full appears in the display when the memory is full If the button 2 is pressed and no program is to be entered press the Ch button 6 and then the Pr button 8 to get out of the program mode To check the programs Press the Ch button 6 An I 12 and an O 15 are displayed Press the Ch button 6 again The contact closing and contact opening information for the first program is displayed Continued pressing of the Ch button 6 causes the display to sequence through all of the pro grams in memory If ten programs have been entered the word Full appears after the tenth program display Press the Pr button 8 to return to the time of day display To change edit a program Press the Ch button 6 until the program you want to change appears in the display window Press the I O button 2 to select contact clos ing or contact opening time Press the h 3 m 4 or 1 7 5 and Q 7 but tons to change the hour minute or day Press the Pr button 8 to enter the edited pro gram and return to the time of day display To erase clear a program Press the Ch button 6 until the program to be erased is displayed Press the C button 10 with a ball point pen to clear the program Press the Pr button 8 to return to the time of day display Redistribution or publication of this document by any means i
87. and to the opposite side to send a stop signal In addition to start and stop functions the control has an over crank relay a preheat relay two Timing lamps a Lockout lamp a Reset switch a preheat delay On Off switch and an Auto Stop Handcrank switch Programmed Transition Option The optional Program Transition module is used to introduce a pause during transition Programmed transition allows the transfer switch to assume a midtransition position for an adjustable interval of time In this position the load is not connected to either power source Normal or Emergency This feature allows residual voltage from inductive loads to decay to an acceptable level before transfer is completed Signal Module Option The main function of the optional Signal Module is to delay transfer or retransfer for a preset time while operating a signal contact to give warning that a transfer or retransfer is about to occur This op tion is typically used in elevator applications Float Battery Charger Option The optional float charge battery charger regulates its charge voltage to continuously charge without damage to the battery As the battery approaches full charge the charging current automatically ta pers to zero amperes or to steady state load on the battery The battery charger has an ammeter for in dication of charging current and has a fuse for protection of the battery charger circuit Auxiliary Relays Option Optional aux
88. ansfer time delay is timing This pause before transferring the load to the generator is to allow the generator set to stabilize Transfer of Load After the transfer time delay has timed out the time delay module sends out a trans fer signal If the optional Signal Module is not used the transfer signal energizes the transfer control relay K14 If the Signal Module is used the transfer signal is delayed for a preset time 0 50 seconds During this delay the Signal Module energizes an Elevator Signal relay to announce that a transfer is about to occur When K14 is energized with or without the Signal Module delay its normally open contacts close and energize transfer relay K2 When K2 is energized its contacts direct Emergency power to the linear actuator transferring the load to the Emergency source Without programmed transition the linear actua tor circuit path includes K2 contacts circuit breaker CB1 Motor Disconnect switch S1 and auxiliary switch S8 Capacitor s C1 provides the phase shift necessary to drive the linear actuator If the Program Transition module is used there is a pause 0 to 60 or 0 to 7 5 seconds at the neutral position The timing of this pause is controlled by the Program Transition module The linear actuator drive circuit is controlled by K2 K3 and auxiliary switch S5 With programmed transition the circuit path pro vided by the normally closed contacts of K3 and auxiliary switch S5
89. any means is strictly prohibited UTILITY TO GENERATOR SET CUSTOMER CONNECTIONS MOUNTED ON LEFT SIDE OF CONTROL PLATE 34 CUSTOMER MUST MOUNT AND WIRE LAMPS SWITCHES SHIPPED LOOSE NORMAL POSITION EMERGENCY POSITION NORMAL AVAILABLE EMERGENCY AVAILABLE TEST NORMAL RETRANSFER SWITCH OPTIONAL AUTO MANUAL SWITCH AUTO MANUAL SWITCH NONAUTOMATIC CUSTOMER CONNECTIONS MOUNTED ON LEFT SIDE OF CONTROL PLATE zx CUSTOMER MUST MOUNT AND WIRE LAMPS SWITCHES SHIPPED LOOSE NORMAL POSITION STANDBY POSITION NORMAL AVAILABLE STANDBY AVAILABLE 512 NORMAL STANDBY SWITCH 514 LOCAL REMOTE SWITCH 514 SHOWN IN THE REMOTE POSITION OPEN CONSTRUCTION WIRING DIAGRAMS Power 8 11 Generation O gt nM E E X CLOSED Pd lt Sz gt uo R E M 0 T E X CLOSED UTILITY TO UTILITY CUSTOMER CONNECTIONS MOUNTED ON LEFT SIDE OF CONTROL PLATE 7 CUSTOMER MUST MOUNT AND WIRE LAMPS SWITCHES SHIPPED LOOSE SOURCE 1 POSITION SOURCE 2 POSITION SOURCE 1 AVAILABLE SOURCE 2 AVAILABLE PREFERRED SOURCE SELECTOR SWITCH 512 SHOWN IN THE SOURCE 1 POSITION OPTIONAL AUTO MANUAL SWITCH PERFERRED SOURCE SELECTOR SWITCH AUTO MANUAL SELECTOR SWITCH moncog E r X CLOSED r gt C z gt x m o gt c o X CLOSED MOMENTARY CONTACT SPRING RETURN TO CENTER GENERATOR SET TO GENERATOR SET CUSTOMER CONNECTIONS MOUNTED ON LEFT SIDE OF CO
90. at Battery Charger The optional float charge battery charger Figure 2 10 regulates its charge voltage to continuously charge the battery As the battery approaches full charge the charging current automatically tapers to zero amperes or to steady state load on the battery There are two chargers available One battery charger is rated for 10 amperes at 12 or 24 VDC The other battery charger is rated for 2 amperes at 12 or 24 VDC Power to the battery charger is supplied directly from the Normal source through connector J1 P1 on the Accessory Control Panel The output of the battery charger is connected to the GND and B ter minals of TB2 or if the 3 Wire Start module is used Refer to the drawing referenced on sheet 3 of your schematic and wiring diagram package The 2 ampere battery charger has an ammeter to indicate charging current and a fuse to protect the battery charger circuit The 10 ampere battery charger has three fuses two on the AC input and one on the DC output three fault display LEDs and an ammeter for indica tion of charging current On the 10 ampere charger three sets of form C alarm contacts corresponding to the three fault LEDs are also available These contacts can be wired by the installer to activate other audible or visual alarms An optional harness and contact block is required Under normal operating conditions the Low Bat and AC Fail relays are energized and the High Bat relay
91. atically by the opening of contacts in the exerciser clock When ground is removed from K13 8 its normally closed contacts close If the test exercise was con ducted without load then the closure of contacts K13 2 K13 3 energizes two wire start relay K11 which removes the two wire start signal and if ap plicable sends a stop signal to the 3 Wire Start module If the test exercise was conducted with load then the closure of contacts K13 6 K13 7 provide a path for A B phase power to the bridge rectifiers This al lows the source 1 sensor to sense Normal power and begin retransfer timing Power Generation Meanwhile the closure of K13 2 K13 3 contacts does not energize K11 because contacts K16 2 K16 4 are open and because there is no stop signal being sent from the time delay module J2 13 K16 stays energized and its contacts stay open as long as the transfer switch is in the Emer gency position After the retransfer delay has timed out the time delay module signals relay K15 and retransfer to the Normal power source occurs After retransfer K16 is de energized and contacts K16 2 K16 4 close The closure of these contacts completes the circuit to K11 After the stop time delay times out the time delay module sends out a stop signal 02 13 that passes through contacts K13 2 K13 3 and K16 2 K16 4 This signal terminates both two wire and three wire start signals Instant Retransfer When testing with load you
92. ation To set the pickup and dropout percentages align the slots on the potentiometers with the desired markings on the Power Sentry cover Figure 2 14 Overvoltage Sensor Calibration The optional overvoltage sensor monitors the source voltage for an overvoltage condition To cali brate the overvoltage sensor If the undervoltage sensor has not been calibrated do so before proceeding 1 Check that nominal voltage is present on all phases of the source being calibrated Normal or Emergency On voltage sensors with the frequency sensing option the source frequen cy must be within the limits set by the Frequen cy Bandwidth potentiometer 2 Turn the Overvoltage Dropout and Delay po tentiometers fully counterclockwise 3 Turn the Overvoltage Cal potentiometer fully clockwise The Source Available lamp for the selected source should light 4 Turn the Overvoltage Cal potentiometer coun terclockwise until the Source Available lamp turns off 5 Slowly turn the Overvoltage Cal potentiometer clockwise until the Source Available lamp just turns on again Overvoltage Dropout and Time Delay Adjustments The overvoltage sensor has an adjustable dropout and time delay Dropout occurs when an overvol tage condition is sensed The dropout time delay al lows the control to ignore momentary voltage over shoots Pickup is fixed at five percent below the dropout setting Overvoltage dropout and time delay are adjustable over
93. ator motor to the switch assem blies using hex head capscrews 4 lock wash ers 4 flat washers 4 barriers 2 and spacers 4 Tighten the capscrews to 25 to 27 in lbs 2 8 to 3 0 Nem 4 Connect the black actuator lead wire to the cir cuit breaker and the red and white actuator lead wires to the following capacitor terminals Red Lead Wire Connect to capacitor C1 Ter minal 1 White Lead Wire If one capacitor connect to capacitor C1 Terminal 2 If two capacitors connect to capacitor C2 Terminal 2 Transfer switches for voltage ranges 347 380 416 and 440 480 use two capacitors C1 and C2 wired together in series A single jumper wire is placed between terminal 2 on C1 and ter minal 1 on C2 5 Replace the capacitor end cap s and install the capacitor s in the bracket s Redistribution or publication of this document by any means is strictly prohibited QT 9 42 RODEND a ASSEMBLY LINEAR DOE ACTUATOR rsen o ACTUATOR LI ROD BARRIER 2 al T EMERGENCY TERMINAL SPACER BRACKET D TORQUE 70 TO 75 IN LBS 7 9 TO 8 5 Nem 2 TORQUE 25 TO 27 IN LBS 2 8 TO 3 0 Nem S TORQUE 25 TO 30 IN LBS 2 8 TO 3 4 Nem 5 1558 FIGURE 4 6 TRANSFER SWITCH COVER 150 TO 260 AMPERES D OV J 4 A t h ic 4 10 Redistribution publication of this document Generation by
94. b ERR M C E PERUENIRE 1 1 About TS Manual ua u usan caca samedi n Rae deck rac ose tardus o deat d usa dean 1 1 Transfer Switch Application i e RR RR 1 1 Automatic Transfer Switches 20425022 etae RR 1 2 erg Seeded wees 1 2 Transfer Switch Assembly RR Rer kenge reed 1 4 uu da CS Avv Bo whe Deas Ze 1 4 sos korean ed Santa e mde seu aded ied deri ara E apps died aat s ias hee Rea 1 7 Preventive Maintenance 1 9 Removing and Replacing Electronic Control Components 1 10 Model Identification MT Tc DEEST 1 10 Feature Description Feature Option 1 11 2 ELECTRONIC CONTROL SYSTEM 2 1 INTFOGUCHION PPP cT 2 1 Power Sentry Control uiis oss ese sees e ER ras 2 1 Accessory Control Panel and Terminal Blocks 2 7 Optional Control Modules and Accessories 2 8 Control System Operation 00 0 cece eee eee 2 17 Adjusting Power Sentry Modules 2 22 Adjusting Optional Control Modules and Accessories 2 24 3 TROUBLESHOOTING
95. bat tery charger to its AC power source e Reconnect the Normal power source and Emergency power source e Place the operation selector switch in the Re mote position AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death Use extreme cau tion to avoid touching electrical contacts whenever the cabinet door is open LINEAR ACTUATOR REMOVAL AND REPLACEMENT 40 to 125 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the linear actuator for 40 to 125 am pere switches Removing Actuator 1 Open the transfer switch cabinet door 2 Loosen and remove the four machine screws with flat washers that secure the plastic switch cover to the switch base and lift off the cover Separate the actuator lead wires from the rest of the wiring harness Re
96. bed below before mak ing adjustments Place the Motor Disconnect Switch on the acces sory control panel in the Off position when making adjustments Return the switch to the Auto position after adjustments are completed Available 0 Pickup Noval I 5 omina Cal Dropout 85 of Pickup 210 Bandwidth o Nominal 20 15 0 Delay Seconds 1 115 Dropout of Nominal 125 Delay Seconds gt is UO tz o G o gt i gt Start Gen Set Pickup Delay Seconds Nominal Cal Timing Delay Dropout Minutes Bandwidth Timing of Nominal Complete Delay Seconds Delay Minutes Dropout Nominal Timing Complete Cal Delay Delay Seconds Seconds Overvoltage Frequency Undervoltage E SC1574 FIGURE 2 14 POWER SENTRY ADJUSTMENTS Po wer Generation 2 22 by any means is strictly prohibited Redistribution or publication of this document 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 when the cabinet door is open Undervoltage Sensor Calibration The standard voltage sensor modules monitor the Normal and Emergency power sources for an un dervoltage condition To calibrate the undervoltage sensors 1 Check that nominal
97. bited position a local test or exercise signal will energize K13 The Remote Test input has no corresponding With Without Load switch This input is connected direct ly to relay K18 Without Load Test If the appropriate With Without Load switch S1 or S4 is in the Without Load posi tion a local test or exercise signal will energize K13 When K13 is energized its normally closed con tacts open When contacts K13 2 K13 4 open K11 the normally energized two wire start relay is de energized When K11 is de energized a start signal is sent to the generator set If applicable a start signal is sent to the 3 Wire Start module With Load Test Locate contacts K10 2 K10 4 and K18 2 K18 4 These two sets of contacts along with a set of K12 contacts provide the two circuit paths for the phase A B Normal side bridge rectifier at CR16 CR17 The bridge rectifier in turn pro vides a sampling voltage to the Normal side voltage sensor Whenever the transfer switch is connected to the Normal source 1 source relay K10 is energized and contacts K10 2 K10 4 are open Under these conditions contacts K18 2 K18 4 provide the only circuit path for Normal phase A B power to the bridge rectifier If the appropriate With Without Load switch S1 or S4 is in the With Load position a local test or exer cise signal will energize K18 Because the Remote Test input is connected directly to relay K18 a Re mote Test signal will also ene
98. bled only manual re transfer using the Test Normal Retransfer switch is possible In the event of generator set failure however the Power Sentry control logic will ignore the Auto Manual switch and initiate retransfer to utility power Refer to section 6 for a description of the optional Auto Manual switch on ultility to utility transfer switches Redistribution or publication of this document by any means is strictly prohibited NORMAL sana m EMERGENCY CONNECTED LAMP NORMAL e EMERGENCY AVAILABLE LAMP Onon AVAILABLE LAMP Transfer Switch OPTIONAL AC VOLTMETER SWITCH OPTIONAL AC AMMETER PHASE SELECTOR eee SWITCH FOR OPTIONAL FREQUENCY OPTIONAL METERS METER OPTIONAL TEST NORMAL AUTO MANUAL es E RETRANSFER SWITCH M1694 4s FIGURE 1 2 UTILITY TO GENERATOR SET TRANSFER SWITCH CABINET EXTERIOR Po wer CP E 1 3 Redistribution or publication of this document Generation by any means is strictly prohibited TRANSFER SWITCH ASSEMBLY The transfer switch Figure 1 3 opens and closes the contacts that transfer the load between Normal and Emergency power The transfer switch is me chanically interlocked to prevent simultaneous closing to both power sources The main parts of the transfer switch discussed here are the contact assemblies linear actuator capacitor s Motor Disconnect switch auxiliary switches and auxiliary contacts Transfer switch assembly maintenance procedu
99. c and wir ing diagram package FIGURE 7 6 PROGRAM TRANSITION MODULE Alarm Module Option The optional alarm module Figure 7 7 provides an audible indication that the transfer switch has trans ferred to the Standby power source A push button on the alarm module provides a means to silence the horn The Alarm lamp indicates that the transfer switch is in the Standby Connected position If the horn is si lenced the Horn Silenced lamp will also light Both lamps will stay lit until the transfer switch moves O from the Standby Connected position to the discon Push To nected neutral or Normal Connected position O Horn oed nu 300 3998 FIGURE 7 7 ALARM MODULE wer 7 6 Redistribution or publication of this document Generation by any means is strictly prohibited X lt 1 Y OPERATION Local Operation Transfer switch operation results in rapid movement of the manual operator han dles and presents a hazard of severe personal injury Keep the cabinet door closed To set the transfer switch for local operation 1 Place the Local Remote switch in the Local position 2 Place the Motor Disconnect switch on the Ac cessory Control Panel in the Auto position To transfer the load to the Standby source 1 Check that the Standby Available lamp is lit The transfer switch will only permit transfer to the Standby source if the Standby source volt age is available 2 Move the
100. c switch covers in position and secure with machine screws and flat washers Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque Redistribution or publication of this document by any means is strictly prohibited SC1570s 347 480V SERIES NORMAL EMERGENCY VIEW A A WARNING 3 3 LIE H er 115 240V PARALLEL LINEAR ACTUATOR ROD END ASSEMBLY ROD CAPSCREW tr E lt D lt ACTUATOR CAPSCREW wt a d p A LES gai iu E 1 1 Redistribution publication of this document by any means is strictly prohibited 16 TRANSFER SWITCH COVER 800 1000 AMPERES 4 26 FIGURE 4 D TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem 2 TORQUE TO 70 TO 75 IN LBS 7 9 TO 8 5 Nem Power G eneration X gt Oo 4 w 7 Insert the actuator rod into the replacement ac tuator motor Figure 4 17 Hold the actuator ground brush up slightly to allow passage of the actuator rod Secure the rod end assembly to the actuator rod with the hex head capscrew flat washer and lock washer Tighten the capscrew to 70 to 75 in Ibs 7 9 to 8 5 Nem torque Fit the rod as sembly into the handle of the closed switch as sembly ROD END ASSEMBLY ACTUATOR
101. calibration and troubleshooting in sections 1 2 and 3 is applicable Refer to this sec tion 6 for an overview of the utility to utility transfer switch Refer to the five sheet schematic and wir ing diagram package that was shipped with the transfer switch for specific information about its configuration Section 4 of this manual covers transfer switch as sembly service procedures for all configurations Transfer Switch Application SOURCE 2 Transfer switches are an essential part of a build spem ings standby or emergency power system The Normal power source source 1 is backed up by an FIGURE 6 1 LOAD TRANSFER SWITCH Emergency power source source 2 A transfer oe switch supplies the electrical load with power from one of these two power sources The load is con nected to the common of the transfer switch Figure 6 1 Under normal conditions the load is supplied with power from the Normal source as illustrated If the Normal power source is interrupted the load is transferred to the Emergency power source When Normal power returns the load is retransferred to the Normal power source The transfer and retran sfer of the load are the two most basic functions of a transfer switch Utility to Utility Transfer Switches Utility to utility transfer switches capable of auto matic operation without operator involvement per form the following basic functions 1 Sense the interruption of the Preferred
102. ce An adjustable time delay 0 to 120 seconds over rides momentary overshoots in voltage To set this time delay align the slot on the poten tiometer with the desired marking on the Power Sentry cover Overvoltage adjustment and calibration proce dures are described in section 2 Frequency Sensing With optional frequency sensing the source 1 and source 2 power sources are monitored for variations in frequency The sen sors determine whether the source is within an ad justable bandwidth As with the standard undervoltage sensing the fre quency sensors signal the time delay module which controls the transfer or retransfer sequence An adjustable time delay 0 to 15 seconds allows the control to ignore momentary dips or rises in fre quency To set this time delay align the slot on the poten tiometer with the desired marking on the Power Sentry cover Redistribution or publication of this document by any means is strictly prohibited pa Programmed Transition Option The optional Program Transition module Figure 6 4 is used to introduce a pause during transition Programmed transition allows the transfer switch to assume a mid transition position for an adjustable interval of time In this position the load is not con nected to either power source This feature allows residual voltage from inductive loads to decay to an acceptable level before transfer is completed The length of time that the transfe
103. ce in hertz Phase Selector Switch This switch is used to se lect the source 1 or 2 and phase to be measured On transfer switches with an AC ammeter the load wires must each pass through a current transform er TRANSFER SWITCH The transfer switch Figure 6 3 opens and closes the contacts that transfer the load between source 1 and source 2 power The transfer switch is mechan ically interlocked to prevent simultaneous closing to both power sources The main parts of the transfer switch discussed here are the contact assemblies linear actuator Motor Disconnect switch and auxil iary contacts Contact Assemblies The automatic transfer switch has either three or four poles Three pole transfer switches are pro vided with a neutral bar The contact assemblies make and break the current flow When closed to either the source 1 or the source 2 power source the contacts are mechanically held A mechanical interlock prevents them from closing to both power sources at the same time Linear Actuator The linear actuator is a linear induction motor that moves the contact assemblies between the Normal source 1 power source and the Emergency source 2 power source Linear actuator operation is initiated automatically with automatic transfer switches Manual operation of the transfer switch is also possible Refer to Manual Operation in the Op eration section Motor Disconnect Switch The Motor Disconnect toggle switch
104. ce voltage is present Manual Operation The transfer switch has operator handles for manu ally transferring the load Use the following proce dure 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 If possible remove all AC power to the transfer switch before manually operating the switch If it is necessary to perform manual operation with AC power connected follow the Safety Related Work Practices listed in NFPA 70E 1 Place the Local Remote switch in the Local position 2 Open the cabinet door of the transfer switch 3 Move the Motor Disconnect switch to the Off position 4 Transfer from the Normal to the Standby power source A Pull the upper manual operator handle down B Push the lower manual operator handle down Retransfer from the Emergency to the Nor mal power source C Pull the lower manual operator handle up D Push the upper manual operator handle up Transfer switch operation re sults in rapid movement of the manual op erator handles and presents a hazard of se vere personal injury Keep hands clear of handles when switching back to Auto 5 To return to electrical operation move the Mo tor Disconnect switch to the Auto position 6 Close and lock the cabinet door 7 If remote control operation is being use
105. ch is in the Emergency position switches S6 S7 S8 and S9 are actuated Refer to Section 2 and Power Generation to the schematic and wiring diagram package for more information on the functions of the individual switches The schematic and wiring diagram package is shipped with the transfer switch Contact your dis tributor if you do not have a set of drawings Refer to Section 4 for a description of auxiliary switch main tenance procedures Auxiliary Contacts Auxiliary contacts are provided on the Normal switch S2 and Emergency switch S6 sides of the transfer switch They are actuated by operation of the transfer switch during transfer and retransfer The Normal side auxiliary contact switch is actuated when the transfer switch is in the Normal position The Emergency side auxiliary contact switch is ac tuated when the transfer switch is in the Emergency position The auxiliary contacts have current ratings of 10 amperes at 250 VAC ELECTRONIC CONTROL Figure 1 3 shows the interior of a 125 ampere util ity to generator set transfer switch Due to differ ences in cabinet sizes the location of some of the optional modules in your transfer switch may not be the same as shown here Refer to section 5 6 or 7 if applicable The most important component of the electronic control system is the Power Sentry Control The Power Sentry includes voltage sensing circuits time delay circuits and control relays T
106. contacts Source 1 Available Source 2 Available Test Exercise e Backup Source Available These relays are not affected by the Elevator Signal delay They respond directly to signals from the Power Sentry The Source 1 and Source 2 Available relays are en ergized whenever their respective power sources are producing power In utility to generator set applications the Source 2 Available and Backup Source Available relays op erate identically The Test Exercise relay is energized whenever the system is in test or exercise mode Refer to section 5 or 6 for a description of generator set to generator set or utility to utility signal mod ules All relay contact connections are made at TB3 Re fer to sheet 1 of your schematic and wiring diagram package Power Generation 2 11 Signal Module No rnDelay asia 16 Timing SC1584 Delay Seconds FIGURE 2 6 SIGNAL MODULE Redistribution or publication of this document by any means is strictly prohibited Exerciser Clock The optional exerciser clock Figure 2 7 initiates generator set start run cycles at programmable in tervals and for programmable durations It is a mrn 9 7 day 24 hour clock that can store and execute up I epu to ten start stop programs exercise cycles 1 23 4567 m nm D is Instead of an exerciser clock generator set to gen o LILI erator set transfer switches may include an optional
107. control panel The K16 run interlock relay is energized whenever the transfer switch is in the Emergency position When energized its contacts 2 and 4 are open This functions to prevent generator shut off until re transfer to the Normal side occurs There are two run interlock relays on the generator set to generator set mother board Additional outputs from the mother board include e Start Genset outputs e Source 1 and 2 Available outputs e Transfer and Retransfer outputs e Backup Source Failure outputs Start Genset and Source 2 Available outputs are available for connection to the optional 3 Wire Start module The generator set to generator set mother board includes a Start Genset 1 output and a Start Genset 2 output These two outputs as well as Source 1 and Source 2 Available outputs are available for connection to the two optional 3 Wire Start mod ules Start Genset Source 1 Available Source 2 Avail able Transfer Retransfer and Backup Source Fail ure outputs are available for connection to the op tional Signal Module relay board Voltage Sensor Modules The voltage sensors are plug in modules that fit into the J1 and J3 edge connectors on the mother board The voltage sensors monitor the voltage sources single or three phase and provide an out put signal Source Available when the source is within predetermined limits Depending on the op tions selected the sensors test for undervoltage overvolta
108. 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 Power Sentry calibration procedures are described in section 2 The most important component of the electronic control system is the Power Sentry control Figure 5 3 The Power Sentry includes voltage sensing circuits time delay circuits and control relays There are also several adjustment potentiometers and indicator lamps on the Power Sentry The ad justments must be performed only by qualified ser vice personnel Accidental actuation of the linear motor can cause severe personal injury Dis able the motor as described below before mak ing any adjustments Place the Motor Disconnect Switch Figure 5 3 in the Off position when making adjustments Return the switch to the Auto position after ad justments are completed Redistribution or publication of this document by any means is strictly prohibited OPTIONAL OPTIONAL 3 WIRE PROGRAMMED START OR TRANSITION SIGNAL MODULE INDICATOR LAMPS OPTIONAL METERS OPTIONAL 3 WIRE START OPTIONAL SWITCHES ACCESSORY CONTROL PANEL MOTOR DISCONNECT SWITCH POWER SENTRY CONTROL AUTOMATIC TRANSFER SWITCH SC1581 3s FIGURE 5 3 GENERATOR SET TO GENERATOR SET TRANSFER SWITCH
109. covers troubleshooting procedures for the utility to generator set automatic transfer switch Although some of the information is applicable to generator set to generator set utility to utility and nonautomatic remote configurations there are several significant differences Refer to section 5 for an overview of generator set to generator set transfer switch troubleshooting Refer to section 6 for an overview of utility to utility transfer switch troubleshooting Refer to section 7 for an overview of nonautomatic remote transfer switch troubleshooting Refer to the five sheet schematic and wiring dia gram package that was shipped with the transfer switch for specific information about its configura tion 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 when the cabinet door is open Remove power to the door by discon necting connector J1 P1 on the accessory con trol panel before removing and replacing com ponents The following procedures are to be performed only by technically qualified person nel Improper operation of the generator set presents a hazard that can cause severe per sonal injury or death Observe all safety pre cautions in your generator set manuals This troubleshooting procedure asks questions that can be answered with a YES or a NO The numbers in
110. crews that secure the interlock arm to the block and cross bar assemblies and lift off the interlock arm 13 Remove the hex head capscrews ring termi nals spring washers and lug terminals from the block and cross bar assembly Redistribution or publication of this document by any means is strictly prohibited JUMPER LOAD BUS NEUTRAL BUS BARS BARS BAR NEUTRAL O NORMAL EMER NORMAL INTERLOCK a INTERLOCK BAR 2 1 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem 2 TORQUE TO 10 TO 12 FT LBS 13 6 TO 16 3 Nem S TORQUE TO 15 TO 20 IN LBS 1 7 TO 2 3 Nem TORQUE TO 70 TO 75 IN LBS 7 9 TO 8 5 Nem sc1560 FIGURE 4 8 3 POLE SWITCH ASSEMBLY 150 TO 260 AMPERES 5 Power Tm TNT ue e RR 4 13 Redistribution or publication of this document Generation by any means is strictly prohibited JUMPER LOAD BUS BUS BARS ENS 2 19 167 ore gras d P EI Salis Do E o 9N ZR ii q mp G d q ep INTERLOCK ARM INTERLOCK BAR 4 10 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem 2 TORQUE TO 10 TO 12 FT LBS 13 6 TO 16 3 Nem S TORQUE TO 15 TO 20 IN LBS 1 7 TO 2 3 Nem 4 TORQUE 70 TO 75 IN LBS 7 9 TO 8 5 Nem 5 1809 FIGURE 4 9 4 POLE SWITCH ASSEMBLY 150 260 AMPERES T 4 14 Redistribution or publica
111. ct it from its AC power source Then disconnect the set starting battery negative lead first AWARNING AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the block and cross bar assemblies for 150 to 260 ampere switches Removing the Block and Cross Bar Assembly Normal or Emergency 1 Loosen the lug terminal screws and remove the power source supply wires from the lug termi nals 2 Remove the linear actuator as described in the Linear Actuator Removal and Heplacement section for 150 to 260 ampere switches Fol low steps 1 through 7 in the Removing Actuator section 3 Remove the hex head capscrews lock wash ers and flat washers that secure the interlock bar to the interlock arms Figures 4 8 and 4 9 and remove the interlock bar 4 Remove the round head machine screws and mounting plate that secure the handle assem bly to the switch assembly and lift off the han dle assembly 5 Disconnect the control wiring leads from the jumper bus bars 6 Remove the hex head capscrews and spring washers that secure the A B and C jumper bus bars to the block and cross bar assemblies Remove the two Phillips head screws and the two hex head capscrews that secure the load lug support block Carefully remove the j
112. ct the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emergen cy power source Place the operation selec tor switch in the Remote position 9 Test the transfer switch for proper operation and close the cabinet Redistribution or publication of this document by any means is strictly prohibited TORQUE TO 10 TO 15 IN LBS 1 1 TO 1 7 Nem SC1561 BARRIERS FIGURE 4 20 AUXILIARY SWITCH 800 1000 AMPERES E 88 Pow 6 J 4 33 Redistribution or publication of this document Oo Generation by any means is strictly prohibited Power 4 34 Redistribution or publication of this document ion by any means is strictly prohibited 5 GenSet to GenSet INTRODUCTION GENERATOR This section provides information for a transfer SET 1 switch with an automatic generator set to genera tor set control Much of the information on theory of operation Power Sentry calibration and troubleshooting in sections 1 2 and 3 is applicable Refer to this sec tion 5 for an overview of the generator set to gen erator set transfer switch Refer to the five sheet schematic and wiring diagram package that was shipped with the transfer switch for specific informa tion about its configuration I I I I I L Section 4 of this manual covers transfer switch as sembly service procedures for all configurations
113. ctifier is opened These contacts close to initiate retransfer to Normal power if the generator set fails during test or exercise With Without Load With K12 source 2 available relay and K13 test exercise relay energized the only path for phase A B power to the bridge rectifi ers is through switch S1 the With Without Load switch If S1 is closed Without Load position the Power Sentry senses that both sources are available In utility to generator set applications the Power Sentry is configured to prefer Source 1 No transfer of load occurs If S1 is open With Load position there is no path for phase A B power to the bridge rectifier A power failure although simulated is sensed and transfer of load timing begins After the transfer timer times out the time delay module signals relay K14 and transfer of load as described above occurs When the transfer switch is in the Emergency posi and the Emergency source is energized K16 is energized by the action of position sensing auxil iary switch S7 When K16 is energized its run inter lock contacts K16 2 K16 4 are open preventing K11 from being re energized This prevents the control from stopping the generator set as long as it is still powering the load End of Test Exercise The test exercise period is stopped by removing the ground from K13 8 This is done by moving the Test Normal Retransfer switch to Normal by opening the remote test switch or autom
114. d rav VOLTAGE ADJUSTMENT ES1692 SC1613 10 AMP CHARGER 2 AMP CHARGER FIGURE 5 10 BATTERY CHARGER AC LINE FAILURE BATTERY VOLTAGE SC1578 2 FIGURE 5 11 10 AMP CHARGER ALARM CONTACTS Redistribution or publication of this document by any means is strictly prohibited Auxiliary Relays Option Optional auxiliary relays provide contacts for ener gizing external alarms remote indicators and con trol equipment such as louver motors and water pumps Connections to the auxiliary relays are made direct ly to the relay terminals The terminals accept wire sizes from one 18 AWG wire to two 12 AWG wires There are three types of auxiliary relay coils 12 VDC 24 VDC and 24 VAC Table 5 1 lists several auxiliary relay options All relays have two normally open and two normally closed contacts that are rated for 6 amperes at 600 VAC Figure 5 12 SC1576 The AC relays are energized by the same signals that power the corresponding indicator lamps on the cabinet door The Emergency and Normal DC relays are ener gized to indicate transfer switch position The Gen set Run DC relay is energized only when the 2 wire start signal is present at the RMT terminal of TB2 Refer to sheet 1 and to the drawings referenced on sheet 3 of your schematic and wiring diagram pack age FIGURE 5 12 AUXILIARY RELAYS TABLE 5 1 AUXILIARY RELAY OPTIONS 24 24 24
115. d Specification number as shown on the nameplate Electrical characteristics are shown on the lower portion of the nameplate which is located on the cabinet door If itis necessary to contact a dealer or distributor re garding the transfer switch always give the com plete Model Specification and Serial number as listed on the nameplate This information is neces sary to properly identify your unit among the many types manufactured Refer to the next page of this section for a list of feature option codes for transfer switches at spec level J and above Power Generation On spec G and H transfer switches the model number is made up of code segments that desig nate various features or options OT C U 2000 A 00000 G d f 2 3 4 5 6 7 1 OT 3 Pole Transfer Switch Series ON 4 Pole Transfer Switch Series 2 Application Code A Nonautomatic B Utility to Utility C Utility to Genset D Genset to Genset G Remote Control ERS 3 Standards Code U UL Listed C CSA Approved N No Approval Required 4 Ampere Rating B 240 120 Volt C 208 120 Volt D 240 120 Volt E 400 240 Volt F 380 220 Volt G 480 277 Volt H 600 347 Volt 40 260 70 300 100 400 125 600 150 800 225 1000 250 Voltage Frequency Code 60 Hz A 120 Volt 1 Phase 2 Wire 1 Phase 3 Wire 3 Phase 4 Wire 3 Phase 4 Wire 3 Phase 4 Wire 3 Phase 4 Wire 3 Phase 4 Wire 3 Phase 4 Wire R S
116. d place the Local Remote switch in the Remote posi tion Redistribution or publication of this document by any means is strictly prohibited 2 gt TROUBLESHOOTING The following procedures describe preliminary troubleshooting checks ACpower within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal injury or death For this reason do not touch or allow clothing tools or jewelry to contact exposed electrical terminals whenever the cabinet door is open Make sure you are standing on a dry insulating surface Transfer Switch Does Not Transfer to the Standby Source 1 Check the Motor Disconnect switch It should be in the Auto position 2 Are the Local Remote and Normal Standby switches in the correct positions 3 Has the programmed transition time delay if equipped expired Power Generation 7 8 4 Is the Standby source voltage present Check the Standby Available lamp Check the Stand by source voltage 5 Manually transfer the switch see Operation Transfer Switch Does Not Retransfer to the Normal Source 1 Check the Motor Disconnect switch It should be in the Auto position 2 Are the Local Remote and Normal Standby switches in the correct positions 3 Has the programmed transition time delay if equipped expired 4 Is the Normal source voltage present Check the Normal Available lamp Check the Normal source voltage 5 Manually
117. d to the Normal power source The transfer and retransfer of the load are the two most basic functions of a transfer switch Operation of a nonautomatic remote transfer switch is initiated either by an operator at the trans fer switch or by an external signal from a remote source gt GA Pow r 7 1 Redistribution or publication of this document 9 Generation by any means is strictly prohibited CABINET The standard cabinet meets the requirements of the National Electrical Manufacturers Association NEMA for a UL Type 1 cabinet This type is desig nated as a general purpose indoor cabinet Items on the door of a typical cabinet are shown in Figure 7 2 Indicator Lamps There are four indicator lamps on the cabinet door The Normal Available and Standby Available lamps are lit whenever their corresponding power sources are producing power These two lamps can be lit si multaneously The Normal Connected and Standby Connected lamps indicate which power source is connected to the load Only one of these two lamps can be lit NORMAL CONNECTED LAMP NORMAL AVAILABLE LAMP Onon Transfer Switch PHASE SELECTOR SWITCH FOR OPTIONAL METERS LOCAL REMOTE SWITCH Normal Standby Switch This three position spring return to center switch is used to electrically select which source is con nected to the load The Normal position causes the Normal source to be connected The Standby posi tion causes
118. dicator is under the desired day number 5 To enter the complete start stop program press the Pr button 8 If all program require ments have been satisfied the display returns to the time of day If the program requirements are not met the display of the section that needs correction flashes on and off To enter more programs repeat the two 5 step pro cedures A maximum of ten programs can be en tered The same ten programs can be repeated each day The word Full appears in the display when the memory is full If the I O button 2 is pressed and no program is to be entered press the Ch button 6 and then the Pr button 8 to get out of the program mode To check the programs 1 Press the Ch button 6 An I 12 and an O 15 are displayed 2 Press the Ch button 6 again The start and stop information for the first program is dis played 3 Continued pressing of the Ch button 6 causes the display to sequence through all of the pro grams in memory If ten programs have been entered the word Full appears after the tenth program display 4 Press the Pr button 8 to return to the time of day display Co To change edit a program Power Generation 1 Press the Ch button 6 until the program you want to change appears in the display window 2 Press the I O button 2 to select start or stop time 3 Press the h 3 m 4 or 1 7 5 and Q 7 but tons to change the hour mi
119. distribution or publication of this document Generation by any means is strictly prohibited 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 The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components Improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety precautions in your generator set manuals Ignition of explosive battery gases can cause severe personal injury or death Do not smoke or cause any spark or flame while servicing batteries TROUBLESHOOTING 3 6 Generator Set Does not Crank for a Power Failure Test or Exercise Using a Switching Ground Three Wire Starting System This procedure is to be performed with the line voltage available and the Test Nor mal Retransfer switch in the Test position When taking voltage measurements be sure that the probe penetrates the confor mal coating on the boards Is the battery voltage at approximately 12 VDC Charge or replace the battery Is the Auto Handcrank Stop switch on the 3 Wire Start module in the Auto position Place the Auto Handcrank Stop switch in the Auto position
120. document o 4 Generation by any means is strictly prohibited 2 gt AUTOMATIC TRANSFER SWITCHES Automatic transfer switches capable of automatic operation without operator involvement perform the following basic functions 1 Sense the interruption of the Normal power source 2 Send a start signal to the generator set Emer gency power source 3 Transfer the load to the Emergency power source 4 Sense the return of the Normal power source 5 Retransfer the load to the Normal power source 6 Send a stop signal to the generator set CABINET The standard cabinet meets the requirements of the National Electrical Manufacturers Association NEMA for a UL Type 1 cabinet This type is desig nated as a general purpose indoor cabinet The door of a typical utility to generator set cabinet is shown in Figure 1 2 Refer to section 5 6 or 7 if applicable Indicator Lamps There are four indicator lamps on the cabinet door The Normal Available and Emergency Available lamps are lit whenever their corresponding power sources utility or generator set are producing pow er These two lamps can be lit simultaneously The Normal Connected and Emergency Con nected lamps indicate which power source is con nected to the load Only one of these two lamps can be lit Test Normal Retransfer Switch This switch has three positions In the Normal posi tion the transfer switch is set for automatic opera t
121. ds can be verified by observing the indicator lamps on the Power Sentry Control The mother board schematic Section 8 and your schematic and wiring diagram package will help you follow the operation descriptions Normal Power Source Connected to Load On the Power Sentry Control The Source 1 Available lamp is on to indicate that the normal pow er source is within the voltage and frequency set tings of the voltage sensor The Retransfer Com plete lamp is on to indicate that the control is signal ing for the load to be connected to the normal power source retransfer No other Power Sentry indica tor lamps are on The normally energized start relay K11 and the re transfer relay K15 are energized Normal Power Source Interrupted An interruption in power can be defined as not only the complete loss of power but also as any situation where the voltage or frequency are outside the set tings of the voltage sensor The voltage sensor re sponds to all power interruptions by blocking the Source 1 Available signal Source 1 Voltage Sensor The undervoltage sen sor begins timing if the source fails or if the voltage falls below the dropout setting The undervoltage dropout time delay is factory set for 0 5 seconds and is not adjustable Unless power is lost completely both the Source 1 Available lamp and the Retran sfer Complete lamp remain on during the timing pe riod If the voltage returns during the 0 5 second delay the sensor resets
122. e Emergency side Refer to section 7 for a description of the nonauto matic transfer switch Load Shed option Refer to sheets 1 2 and 5 of your schematic and wiring diagram package Power Generation 2 15 SC1576 FIGURE 2 12 AUXILIARY RELAYS TABLE 2 2 AUXILIARY RELAY OPTIONS 24 24 24 24 24 24 24 24 24 12 12 VDC Coil 12 VDC Coil 12 VDC Coil Installed Not Wired Emergency Connected Relay Normal Connected Relay Emergency Source Available Relay Normal Source Available Relay Installed Not Wired Emergency Relay Normal Relay Genset Run Relay Installed Not Wired Emergency Relay Normal Relay Genset Run Relay Redistribution or publication of this document by any means is strictly prohibited Meter Package The optional meter package includes an AC amme ter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltages of the selected power source AC Ammeter The ammeter measures the line cur rents of the load Frequency Meter This meter measures the output frequency of the selected power source in hertz Phase Selector Switch This switch is used to se lect the source and phase to be measured Power to the voltage and frequency meters is sup plied from the connector lugs thr
123. e switch base and lift off the cover Figure 4 6 3 Separate the actuator lead wires from the rest of the wiring harness remove wire ties as re quired 4 Pry the capacitor s loose from the bracket Re move the end cap and disconnect the red and white actuator lead wires from the capacitor terminals 5 Disconnect the black actuator wire from the cir cuit breaker and disconnect the ground wire from the end of the actuator 6 Remove the hex head capscrews flat wash ers and lock washers that secure the actuator to the switch assemblies Figure 4 6 and lift out the spacers 4 and barriers 2 Power Generation 4 9 7 Disengage the actuator rod from the switch handle and remove the actuator from the switch assembly 8 Remove one of the hex head capscrews and lock washers that secure the rod end assembly to the end of the actuator rod 9 Remove the rod end assembly from the actua tor rod Figure 4 6 and slide the rod out of the actuator motor Replacing Actuator 1 Insert the actuator rod into the replacement ac tuator motor Figure 4 7 Hold the actuator ground brush up slightly to allow passage of the actuator rod Install the rod end assembly and tighten the capscrew to 70 to 75 in Ibs 7 9 to 8 5 Nem 2 Hold the actuator motor in position over the switch assemblies so the lead wires are at the bottom and fit the rod assembly into the handle of the closed switch assembly 3 Secure the actu
124. e up 4 Before moving the Motor Disconnect switch back to the Auto position remember the trans fer switch will transfer load to the active power Redistribution or publication of this document by any means is strictly prohibited Y lt source if both power sources available it will transfer the load to the Normal source 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 Move the Motor Disconnect switch to the Auto position 6 Close the cabinet door Generator Set Exercise Run the generator set for at least 30 minutes once each week with at least 50 percent load if pos sible If you do not have an optional exerciser use the Test Normal Retransfer switch to test the gen erator set each week The optional exerciser has preselected exercise periods and exercises the generator set automati cally with or without load depending on the position of the Exercise With Without Load switch If the Normal power source has an interruption while the generator set is exercising without load the auto matic transfer switch will transfer the load to the generator set Generator Set Start Test 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
125. e Test Normal Retransfer switch is optically coupled to the time delay module to override the retransfer time delay On all versions of the mother board the transfer and retransfer inputs are used in conjunction with the optional signal module relay board Refer to Op tional Control Modules in this section Utility to utility and generator set to generator set mother boards include Source 1 and Source 2 se lect inputs These inputs are wired to the Source Selector switch on the cabinet door Refer to sec tion 5 or 6 Generator set to generator set mother boards may include an optional change over clock input Refer to section 5 Switches There are three switches on the 300 3090 mother board and four switches on the 300 3953 mother board On the 300 3090 mother board Switch S1 is the With Without Load selector When the switch is in the With Load position test and exercise functions include the transfer of load to the Emergency side When S1 is in the Without Load position test and exercise functions start and run the generator set but do not transfer the load On the 300 3953 mother board Switch S1 is the Ex ercise With Without Load selector When this switch is in the With Load position the exercise function includes the transfer of load to the Emer gency side When 51 is in the Without Load posi tion the exercise function starts and runs the gener ator set but does not transfer the load On the 300 3953 mother
126. e backup 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 Lan Pm 28 Power 1 9 Redistribution or publication of this document Generation by any means is strictly prohibited REMOVING AND REPLACING ELECTRONIC CONTROL COMPONENTS AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal injury or death Disconnect connector J1 P1 before working on the electronic control system Disconnecting J1 P1 removes all power to the door except for customer introduced power at the Signal Module Be sure to remove all power before replacing components No special tools are required to remove and replace control system components The mother board and transformer assembly are held in place by several screws and will not fall when the four screws that secure the Power Sentry cover are removed Be sure to use all of the hard ware when remounting components TABLE 1 2 LUG TIGHTENING REQUIREMENTS SET SCREW SOCKET SIZE ACROSS FLATS MINIMUM TORQUE FOR PROPER OPERATION 3 16 IN 80 IN LBS 9 Nem 1 4 IN 200 IN LBS 23 Nem 5 16 IN 275 IN LBS 31 Nem 3 8 IN 375 IN LBS 43 Nem 1 2 IN 500 IN LBS 57 Nem 9 16 IN 600 IN LBS 68 Nem MODEL IDENTIFICATION Identify your model by referring to the Model an
127. e measurements be sure that the probe penetrates the conformal coating on the boards 15 there a jumper or some kind of a closed circuit connected between TB2 5 and TB2 6 Install a jumper between TB2 5 and TB2 6 If the voltage sensor is still inop erative go to Step 3 Are the proper generator voltages present at the Emergency lugs of the trans fer switch Are the proper generator voltages present at transformer assembly terminal block A1 TB11 located below the mother board Refer to sheet 3 of 5 in your schematic and wiring diagram package Is there 15 to 25 VAC on the mother board between CR29 Cathode and CR33 Cathode CR31 Cathode and CR35 Cathode CR37 Cathode and CR39 Cathode Is there approximately 12 VDC between the CR28 anode on the mother board and ground With the voltage sensor removed from slot J3 on the mother board is there 15 to 25 VDC between J3 14 J3 15 J3 16 and ground and 20 to 30 VDC be tween J3 17 and ground If voltages are OK put the board back in slot J3 If the sensor module is equipped with frequency sensing is the frequency within limits Recalibrate the sensor If it can t be calibrated then replace the sensor and calibrate the new one Find and repair an open in the wiring between the Emergency lugs on the transfer switch and the transformer assembly terminal block located below the mother board Replace the mother board and recalibrate the voltage sensors Pe
128. e penetrates the conformal coating on the boards Does the generator set crank using the generator set Start switch Check the battery voltage If the battery is low then charge it or replace it If battery is OK then there is a problem with the generator set Consult the gener ator set manual Check the wiring from the battery to the transfer switch 4 Is there a jumper or closed circuit between TB2 B and TB2 2 There should NOT be a jumper between TB2 GND and TB2 2 Install a jumper between TB2 B and TB2 2 If the generator set does crank then go to Step 6 Is there 12 or 24 VDC between TB2 RMT and ground Are the wires from the generator set starting circuit to TB2 B and TB2 RMT connected properly Connect wires from the generator set starting circuit to TB2 3 and TB2 4 If the set still does not crank then go to Step 9 With the Test Normal Retransfer switch in the Test position is there 12 or 24 if applicable VDC between J7 10 on the mother board and ground 15 there 12 or 24 if applicable VDC between J8 3 located on the mother board and ground There is an open in the wiring from J8 3 on the mother board to TB2 4 on the transfer switch Find and repair it There is an open in the wiring from TB2 2 on the transfer switch to J7 10 on the mother board Find and repair it Replace the mother board and recalibrate the voltage sensors p pm gt pad Power 3 8 Re
129. e switch 14 Remove the shoulder screws and self locking nuts that secure the two halves of the handle assembly together Remove the shoulder screws and lock washers that secure the han dle assembly to the block and cross bar as sembly Slide the two halves of the handle apart and remove them 15 Remove the two round head machine screws that secure the interlock arm to the cross bar assembly and lift of the interlock arm Redistribution or publication of this document by any means is strictly prohibited INTERLOCK CROSSBAR ARM ASSEMBLY INTERLOCK BAR 52 53 54 55 56 57 58 59 BLaci JUMPER ASSEMBLY BUS BAR CHUTE ARC CHUTE BARRIER ARC CHUTE SPACER JUMPER BUS BAR D TORQUE TO 15 TO 20 IN LBS 1 7 TO 2 3 Nem 2 TORQUE TO 28 TO 33 FT LBS 40 0 TO 44 7 Nem 2 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem 5 TORQUE 18 TO 20 FT LBS 24 4 TO 27 1 Nem 8 TORQUE TO 70 TO 75 IN LBS 7 9 TO 8 5 Nem 6 TORQUE TO 10 TO 12 FT LBS 13 6 TO 16 3 Nem SC1567s FIGURE 4 18 3 POLE SWITCH ASSEMBLY 800 1000 AMPERES Po wer E 4 29 Redistribution or publication of this document Generation by any means is strictly prohibited INTERLOCK CROSSB
130. ead wires in place with the rest of the wiring har ness Redistribution or publication of this document by any means is strictly prohibited ACTUATOR ROD CAPSCREW 1 ROD END ASSEMBLY igi tg LINEAR TM ACTUATOR DC n ge ACTUATOR 2 CAPSCREW o azoo z 5 BARRIER a ees o TERMINAL BRACKET 1 TORQUE 70 TO 75 IN LBS 7 9 TO 8 5 Nem 2 TORQUE TO 25 TO 27 IN LBS 2 8 TO 3 0 Nem 3 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem SC1562s FIGURE 4 11 TRANSFER SWITCH COVER 300 TO 600 AMPERES Lan m gt Powe J 4 18 Redistribution or publication of this document OF Generation by any means is strictly prohibited ZA 7 Check the operation of the transfer switch and the alignment of the Actuator rod by manually opening and closing both the Normal and emergency switch assemblies 9 If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emergen cy power source Place the operation selec tor switch in the Remote position Test the switch for proper operation and close the cabinet 8 Install the plastic switch cover on the switch wi
131. ement 300 to 600 Amperes 4 23 Linear Actuator Removal and Replacement 800 and 1000 Amperes 4 25 Block and Crossbar Removal and Replacement 800 and 1000 Amperes 4 28 Auxiliary Switch Removal and Replacement 800 and 1000 Amperes 4 32 y GU Power Redistribution or publication of this document lt Generation by any means is strictly prohibited Table of Contents Continued SECTION TITLE PAGE 5 GENSET TO GENSET 5 1 5 1 Cabinet 5 2 Transfer SWIC EL 5 3 Electronic Control System 5 3 Operation E 5 14 Troubleshooting PT 5 15 6 TIEITY TO UTIEITY latro etr A te UR PERS QS ERES E e SERIE 6 1 pee 6 1 ec 6 2 Transfer Switch PPP m 6 3 Electronic Control System ERES 6 3 Operaatio 6 8 Troubleshooting Rp Faune does 6 8 7 NONAUTOMATIC REMOTE 7 1 7 1 eens 7 2 Transfer Switch 7 3 Optional Control Components
132. ence is initiated The Relay Energized LED is lit during normal op eration In the event that an under voltage phase reversal or loss of one phase is sensed relay dropout occurs within 500 milliseconds on models up to 300 VAC and within 2 0 seconds on models over 300 VAC The phase sequence monitor relay has an under voltage sensing circuit that causes the relay to drop out when 3 phase voltage falls below 9096 of nomi nal If improperly set this could over ride the Power Sentry voltage sensor To prevent this occurrence turn the nominal voltage adjust potentiometer on the phase sequence moni tor relay fully counter clockwise and adjust the Power Sentry undervoltage dropout setting to a higher voltage CAUTION If improperly adjusted the phase sequence monitor could over ride the Power Sentry undervoltage setting possibly result ing in the generator set being started in unin tended situations To prevent this occurrence adjust the relay to a voltage lower than the Pow er Sentry setting Ee kower 1eneration APhase BPhase C Phase 7 N 220 230 0 20 24 200 25 190 270 TURN FULL COUNTER CLOCK TO 2 7 amp 8 307 2840 02 FIGURE 2 PHASE SEQUENCE MONITOR Redistribution or publication of this document by any means is strictly prohibited Supplement 962 1027 Date 5 95 Insert with Title OT III Transfer Switch Manuals Numbers 962 0113 962 0116 962
133. ener ator sets at the same time Linear Actuator The linear actuator is a linear induction motor that moves the contact assemblies between the Normal source 1 side and the Emergency source 2 side Linear actuator operation is initiated automatically with automatic transfer switches Manual operation of the transfer switch is also possible Refer to Manual Operation in the Operation section Motor Disconnect Switch The Motor Disconnect toggle switch on the acces sory control panel enables and disables the linear Power Generation actuator Place the switch in the Auto position to en able the linear actuator Place the switch in the Off position to disable the linear actuator Auxiliary Contacts Auxiliary contacts are provided on the Normal source 1 and Emergency source 2 sides of the transfer switch They are actuated by operation of the transfer switch during transfer and retransfer The Normal side auxiliary contact switch is actuated when the transfer switch is in the Normal position The Emergency side auxiliary contact switch is ac tuated when the transfer switch is in the Emergency position The auxiliary contacts have current rat ings of 10 amperes at 250 VAC Connections for the auxiliary contacts are made on terminal block TB1 Refer to sheet 1 of your schematic and wiring dia gram package ELECTRONIC CONTROL SYSTEM This section describes the standard and optional components of the electronic
134. eneration 5 16 4 Check the appropriate Source Available lamp on the Power Sentry 5 Manually transfer the switch see Operation Generator Set Continues to Run After Completing Duty Cycle 1 Check the position of the generator set opera tion selector switch It should be in the Auto 8 wire start or Remote 2 wire start position 2 The stop time delay function may not have ex pired Check the Stop Timing lamp on the Pow er Sentry If the timer is defective stop the gen erator set with its Start Stop switch Battery Charger Fails to Charge Check the battery charger fuses Replace if neces sary with fuses of the correct rating Fuse Ampere ratings are shown on the charger faceplate Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any spark or flame while servicing bat teries Battery Loses Water The battery charger float voltage could be too high Battery Loses Charge Battery charger float voltage could be too low Redistribution or publication of this document by any means is strictly prohibited 6 Utility to Utility INTRODUCTION This section provides information for a transfer switch with an automatic utility to utility control The utility to utility control automatically directs transfer of the load from one utility power source to another providing nearly continuous power SOURCE 1 Much of the information on theory of operation Power Sentry
135. er Secure the arc chute cover with the two machine screws Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque 7 Connect the control wiring leads to the corre sponding power source terminals Control wires are marked NORM A B C N or EMER A B C N for identification 8 Clean the current carrying surfaces of the jumper bus bars and load bus bars with a wire brush 9 Install the A B and C jumper bus bar load bus bar load lug support block assembly Secure to the block and cross bar assemblies with hex head capscrews and spring washers Tighten to 10 to 12 ft lbs 13 6 to 16 3 Nem torque Se Power Generation cure the load lug support block with the four screws Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem torque 10 Connect the control wiring leads to the corre sponding jumper bus bar terminals Control wires are marked LOAD A B C N for identifica tion 11 Place the handle assembly in position on the block and cross bar assembly and secure with the two machine screws and mounting plate Tighten to 15 to 20 in Ibs 1 7 to 2 3 Nem torque Apply a thin coat of lubricant Onan part number 524 0157 to the slot in the handle 12 Apply thread sealant blue Loctite 242 Onan part number 518 0309 is recommended to the threads of the interlock bar capscrews Install the interlock bar and secure to each interlock arm with a hex head capscrew lock washer and flat washer Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem to
136. er disconnecting all sources of AC power open the transfer switch cabinet door 2 Loosen and remove the two self Locking nuts and the two machine screws with flat washers that secure the plastic switch cover to the switch base and lift off the cover 3 Remove the three machine screws that secure the terminal bracket Figure 4 6 to the base Move the terminal bracket to allow access to the auxiliary switches 4 Remove the control wiring leads from the auxil iary switch terminals Figure 4 10 5 Remove the hex head machine screws that se cure the auxiliary switch assembly bracket to the base 6 Lift out the auxiliary switch assembly 7 Remove the hex head capscrews and nuts that secure the auxiliary switches to the brackets Figure 4 10 and lift out the four auxiliary switches and insulating barriers Replacing Auxiliary Switch Assembly 1 Install the insulating barriers 5 and auxiliary switches 4 in the brackets and secure with hex head machine screws 2 and nuts 2 Tighten to 10 to 15 in Ibs 1 1 to 1 7 Nem Note that each switch must be assembled so the side with two terminals faces inward Figure 4 10 when the auxiliary switch assembly is installed on the base Hold the auxiliary switch assembly in position on the base the side with two terminals must face inward and secure the bracket to the base using the hex head machine screws Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque In
137. erlock arm Figures 4 13 and 4 14 and remove the interlock bar Disconnect the control wiring leads from the jumper bus bars Remove the round head shoulder screws and lock washers that secure the handle assembly to the block and cross bar assembly and lift off the handle assembly Power Generation 4 20 5 Remove the control wiring leads from the pow er source terminals 6 Remove the lug terminal screws and the power supply wires from the lug terminals Remove the lug mounting screws and then remove the solder less lugs from the switch assemblies 7 Remove the hex head capscrews ring termi nals spring washers flat washers lock wash ers and nuts that secure the jumper bus bars to the load bus bars 8 Remove the hex head capscrews and spring washers that secure the jumper bus bars to the block assemblies and lift off the jumper bus bars 9 Remove the four screws lock washers and flat washers that secure the block and cross bar assembly to the base On 4 pole switches remove the screw that secures the small bear ing bracket to the neutral block Figure 4 14 Remove the block and cross bar assembly Save the bearing bracket and screw for reuse Use care when removing the block and cross bar assembly from the base Carefully disengage the crossbar from the auxiliary switch assembly to avoid cracking the switches 10 On 4 pole switches Figure 4 14 Remove the four screws that secure the b
138. es the conformal coating on the boards 1 Are the proper line voltages present at the Normal lugs of the transfer switch Are the proper line voltages present at transformer assembly terminal block A1 TB11 located below the mother board Refer to sheet 3 of 5 in your schematic and wiring diagram package Is there 15 to 25 VAC on the mother board between CR20 Cathode and CR24 Cathode CR22 Cathode and CR26 Cathode CR16 Cathode and CR18 Cathode 15 there approximately 12 VDC between the CR5 anode on the mother board and ground With the voltage sensor removed from slot J1 on the mother board is there 15 to 25 VDC between J1 14 J1 15 J1 16 and ground and 20 to 30 VDC be tween J1 17 and ground If voltages are OK put the board back in slot J1 If the sensor module is equipped with frequency sensing is frequency within limits Recalibrate the sensor module if it can t be calibrated then replace the sen sor module and calibrate the new one Find and repair an open in the wiring between the Normal lugs on the transfer switch and the transformer assembly terminal block located below the moth er board Replace the mother board and calibrate the voltage sensors Perform these steps in the following sequence A Replace the transformer board to mother board ribbon cable B If the source 1 voltage is not sensed replace the transformer assembly and recalibrate the sensors C If the source 1 voltage
139. g the test or exercise signal This is done by moving the Test Normal Retransfer switch to Normal by opening the remote test switch or automatically by the opening of contacts in the exerciser clock If the test exercise was conducted without load then the removal of the ground signal from K13 causes K13 to be de energized closing contacts K13 2 K13 4 The closure of these contacts ener gizes two wire start relay K11 which removes the two wire start signal and if applicable sends a stop signal to the 3 Wire Start module If the test exercise was conducted with load then the removal of the ground signal from K18 causes K18 to be de energized closing its normally open contacts The closure of contacts K18 2 K18 4 provides a circuit path for A B Normal phase power to the bridge rectifiers This allows the source 1 sensor to sense Normal power and begin retransfer timing After the retransfer delay has timed out the time delay module signals relay K15 and retransfer to the Normal power source occurs After retransfer K16 de energized closing contacts K16 2 K16 4 The closure of these contacts com pletes the circuit to K11 After the stop time delay times out the time delay module sends a stop sig nal from J2 13 through contacts K13 2 K13 4 and K16 2 K16 4 to the coil of K11 This signal termi nates the start signal Instant Retransfer When testing with load you can bypass the retransfer delay by moving the Test
140. ge and under overfrequency The Source Available output signal is latched on when all of the pickup requirements for voltage and frequency are satisfied The Source Available output signal re mains on until the voltage or frequency goes be yond the dropout limits for longer than the corre sponding dropout time delay Undervoltage sensing is accomplished by sensing all voltage phases but responding only to the low est one Thus all phases must be above the under voltage pick up point before undervoltage pickup will occur while undervoltage dropout will occur when any of the phase voltages fall below the drop Redistribution or publication of this document by any means is strictly prohibited 2 out point fixed dropout time delay 0 5 seconds elapses before the Source Available output re sponds to an undervoltage condition The sensor is calibrated and the undervoltage pickup and dropout points are adjusted with potentiometers refer to Aqjusting Power Sentry Modules in this section The pickup adjustment range is 85 to 100 of the nominal voltage The dropout adjustment range is 75 to 98 of the pickup setting Overvoltage sensing is accomplished by monitor ing the peak of the combined phase voltages so that the sensor essentially responds to the highest phase The sensor is calibrated and the overvol tage limit is adjusted with potentiometers refer to Adjusting Power Sentry Modules in this section The ove
141. gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the linear actuator for 300 to 600 am pere switches Removing Actuator 1 Open the transfer switch cabinet door 2 Loosen and remove the four machine screws that secure the plastic switch cover to the trans fer switch and lift off the cover Figure 4 11 3 Separate the actuator lead wires from the rest of the wiring harness remove wire ties as re quired 4 Pry the capacitor s loose from the bracket Remove the end cap and disconnect the red and white actuator lead wires from the capaci tor terminals 5 Disconnect the black actuator lead from the cir cuit breaker and the ground wire from the end of the actuator 6 Remove the hex head capscrews flat wash ers and lock washers that secure the actuator to the switch assemblies Figure 4 11 7 Disengage the actuator rod from the switch handle and remove the actuator from the switch assembly Power Generation 8 Remove one of the hex head capscrews and lock washers that secure the rod end assembly to the e
142. gram mode Pr is reached Press the arrow button again to select the desired day To clear the program for the day selected press the plus and set buttons at the same time To Initiate Or Override An Exerciser Change over Program The clock has a built in test feature Once the clock time has been set the set button B can be used to initiate an exercise test changeover or to cancel exercise test changeover in progress Exercise Applications The Load No Load switch on the control circuit board can be set to test the genset with or without load as desired With the normal source connected and available pressing the set button once will initiate an ex ercise test A hand will be displayed in the upper left corner of the display and the On mode will be indi cated inside the ellipse in upper right corner of the display Figure 2 Pressing the set button again will stop the exercise test and the ellipse will indicate the OFF mode To temporarily override an activated exercise pro gram momentarily press the set button A small hand will appear in the upper left corner of the dis play Figure 2 The current program will be overrid den and the clock will automatically set for the next program Momentarily pressing the set button again will return to the current program Changeover Applications Pressing the set but ton once will initiate a changeover A hand will be displayed in
143. grammed to come ON once each week for five minutes a changeover will occur between the generator sets at that time The clock is a 7 day 24 hour clock that can store and execute up to four start stop programs per day one minute minimum duration The clock also has a test feature that can be used to initiate a genset start and run cycle Programming the exerciser change over clock re quires setting the time of day and entering the start and stop times as described in the following sec tions The clock has backup power for a minimum of six hours When the clock is running on backup power the segments around the display will flash on and off After loss of backup power the day and time will have to be reset Exerciser change over programs will not be lost during a power outage programs are stored in EEPROM To Reset The Clock Resetting the clock erases all existing day time and program settings Depress and hold the arrow plus and set but tons simultaneously Release the plus and set buttons while continuing to hold the arrow button When all aspects of the LCD display appear release the arrow button To Set The Day And Time 1 With the clock powered press all three buttons simultaneously to reset the time The time dis play area will show and a small clock symbol will appear in the upper left corner of the display Refer to Figure 1 Power Generation CLOCK Pr INDICATE
144. h ers and lock washers that secure the actuator to the switch assemblies Figure 4 16 and lift out the spacers and actuator motor Replacing Actuator 1 Hold the actuator motor and spacers 4 in position over the switch assemblies with the lead wires at the bottom 2 Secure the actuator motor to the switch assem blies using hex head capscrews 4 lock wash ers 4 and flat washers 4 Tighten the caps crews to 70 to 75 7 9 to 8 5 Nem 3 Connect the black actuator lead wire to the cir cuit breaker and the red and white actuator lead wires to the following capacitor terminals Red Lead Wire Connect to capacitor C1 Ter minal 1 White Lead Wire Connect to capacitor C2 Terminal 2 Transfer switches for voltage ranges 347 380 416 and 440 480 use two capacitors C1 and C2 wired together in series A single jumper wire is placed between terminal 2 on C1 and ter minal 1 on C2 Transfer switches for voltage ranges 115 190 200 208 and 220 240 use two capacitors C1 and C2 wired in parallel Two jumper wires are used One is placed between terminal 1 on C1 and terminal 1 on C2 The other is placed be tween terminal 2 on C1 and terminal 2 on C2 4 Replace the capacitor end cap s and install the capacitor s in the bracket s 5 Connect the ground wire to the end of the ac tuator Use wire ties to hold the actuator lead wires in place with the rest of the wiring har ness 6 Place the plasti
145. he Auto position the switch is closed Refer to sheets 2 and 4 of your schematic and wir ing diagram package Connectors Accessory control panel connectors J1 J2 and J3 are used to connect the electronic control system to the power terminals auxiliary switch contacts lin ear motor and the terminals of TB2 Disconnecting J1 disconnects all line power from the door Refer to sheets 2 and 4 in your schematic and wiring dia gram package Terminal Blocks Terminal block TB4 provides six AC connection ter minals Refer to sheets 2 4 and 5 of your schemat ic and wiring diagram package Terminal block TB1 Figure 2 3 provides the con nection terminals for form C auxiliary switch con tacts Refer to sheet 1 of your schematic and wiring diagrams package Terminal block TB2 on the utility to generator transfer switch provides the connection terminals for two wire start transfer inhibit and remote test Refer to sheet 1 of your schematic and wiring dia gram package Refer to section 5 6 or 7 if applicable Terminal block TB3 Figure 2 3 provides the con nection terminals for the 3 Wire Start Load Shed battery charger alarm contacts and Signal Module borne ort options Refer to sheet 1 of your schematic and wir ing diagram package and to Optional Control Mod ules and Accessories Open Construction On open construction configurations indicator lamps and key switches are connected to TB3 Re
146. he Retransfer Timing Complete lamp lit 15 the Source Available lamp on the Source 1 voltage sensor lit Refer to Source 1 voltage sensor troubleshooting If the unit is equipped with the Auto Manual Retransfer selector switch located on the door is the switch in the Auto position If the unit doesn t have the switch then go to Step 8 Place the Auto Manual Retransfer switch in the Auto position Does the Re transfer Timing lamp on the time delay board come on Does the transfer switch retransfer after the retransfer time delay 8 Replace the time delay board Turn the retransfer delay pot on the time delay board to minimum counter clockwise If the Retransfer Timing Complete lamp doesn t come on within a minute then replace the time delay board If the Retransfer Timing Complete lamp does come on but the transfer switch still doesn t retransfer then go to Step 10 Is the Motor Disconnect Switch on the accessory control panel in the Auto position Place the Motor Disconnect Switch in the Auto position If the transfer switch does not retransfer then go to Step 12 Z Po wer 3 2 Redistribution or publication of this document e w Generation by any means is strictly prohibited 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 The following procedures are to be performed only by technically qualified perso
147. he transfer switch They are actuated by operation of the transfer switch during transfer and retransfer The Normal side auxiliary contact switch is actuated when the transfer switch is in the Normal position The Emer gency side auxiliary contact switch is actuated when the transfer switch is in the Emergency posi tion Connections for the auxiliary contacts are made on terminal block TB1 The contacts have ratings of 10 amperes at 250 VAC Refer to sheet 1 of your schematic and wiring diagram package Redistribution or publication of this document by any means is strictly prohibited EF bo o OPTIONAL PROGRAMMED TRANSITION ax C INDICATOR LAMPS o0 69 OPTIONAL METERS SWITCHES st e ACCESSORY MOTOR CONTROL DISCONNECT PANEL SWITCH TRANSFER SWITCH ASSEMBLY SC1581 1s FIGURE 7 3 NONAUTOMATIC REMOTE CABINET INTERIOR Power Generation Redistribution or publication of this document by any means is strictly prohibited OPTIONAL CONTROL COMPONENTS Remote Control Circuit Connections Remote control circuit connections are made at ter minals 1 2 and 3 of TB2 Figure 7 4 Closing the contacts across terminals 1 and 2 causes transfer to the Normal source Closing the contacts across terminals 1 and 3 causes transfer to the Standby source Terminal 4 of TB2 is not used Terminals 5 and 6 of TB2 are used for the transfer inhibit input with paral leling systems only
148. here are also several adjustment potentiometers and indica tor lamps on the Power Sentry The adjustments must be performed only by qualified service person nel Power Sentry Time Delays Start Time Delay This delay is adjustable from O to 15 or optionally 0 to 90 seconds This brief time delay prevents generator set starting during power interruptions of short duration Timing starts the moment of Normal utility power interruption If the duration of the interruption exceeds the delay time the control system signals the generator set to start Stop Time Delay This delay is adjustable from 0 to 10 minutes It begins timing when the load is re transferred to the Normal power source At the end Redistribution or publication of this document by any means is strictly prohibited of the delay the stop signal is sent to the generator set This time delay allows the generator set to cool down at no load before stopping Transfer Time Delay This delay begins when gen erator voltage and frequency reach the settings of the control After the delay the transfer switch transfers the load to the Emergency power source This brief time delay allows the generator set to sta OPTIONAL PROGRAMMED TRANSITION OPTIONAL SIGNAL MODULE INDICATOR LAMPS OPTIONAL METERS OPTIONAL 3 WIRE START OPTIONAL EXERCISER CLOCK SWITCHES ACCESSORY MOTOR CONTROL DISCONNECT PANEL SWITCH TEST amp EXERCISE WITH WITHOUT L
149. horoughly dust and vacuum all controls meters switching mechanism components interior buswork and connecting lugs b Close the cabinet door and wash exterior surfaces with a damp sponge mild detergent and wa ter Do not allow water to enter the cabinet especially at meters lamps and switches 3 INSPECT Check buswork and supporting hardware for carbon tracking cracks corrosion or any other types of deterioration If replacement is necessary call your dealer or distributor Check stationary and movable contacts If contact replacement is necessary the procedures are described in section 4 of this manual Check system hardware for loose connections Tighten as indicated in step 4 Check all control wiring and power cables especially wiring between or near hinged door 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 PERFORM ROUTINE MAINTENANCE a Tighten buswork control wiring power cables and system hardware as necessary Hardware torque values are given in section 4 of this manual Retorque all cable lug connections Lug torque requirements are listed in Table 1 2 b Service or replace the batteries 5 CONNECT AC POWER AND CHECK OPERATION a Connect the set starting battery negative lead last Connect the normal AC power source enable th
150. ibution or publication of this document by any means is strictly prohibited 1 Y 4 Start the generator set using its start stop trols The Auto Stop Handcrank switch on the 3 Wire Start module must be in the Handcrank position If it does not crank check the starting battery 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 equipment or oth er possible source of ignition near the fuel system Generator Set Scheduled for Duty Cycle Starts But Does Not Assume Load 1 Has the transfer retransfer time delay expired 2 Check the generator set output voltage by ob serving the voltmeter on the generator set or the optional voltmeter on the automatic trans fer switch Open the cabinet door and check to see if the Motor Disconnect switch is in the Auto position AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death For this reason do not touch or allow clothing tools or jew elry to contact exposed electrical terminals whenever the cabinet door is open Make sure you are standing on a dry insulating surface Power G
151. iginal positions The block assemblies are not identical The A and C phase blocks and the neutral block on 4 pole switches are different than the B phase block Refer Power Generation to the parts manual and the part num bers stamped on the replacement block assemblies to make certain that you install new block assemblies in their correct positions Fill the insulator cups that cover and insulate the block assembly mounting screws with adhesive silicone to completely cover the washers and screw heads Install the power source supply wires and se curely tighten the lug terminals to 10 to 12 ft lbs 13 6 to 16 3 Nem torque Connect the control wiring leads to the power source terminals Control wires are marked NORM A B C or EMER for identification Apply a thin coat of electric joint compound be tween the mating surfaces of the jumper bus bars the braided strap connectors and load bus bars Install the jumper bus bars and secure to the switch assemblies with hex head capscrews spring washers and bushings The neutral pole on 4 pole switches does not have a bush ing at this connection Tighten to 18 to 20 ft lbs 24 4 to 27 1 Nem torque Secure the jumper bus bars to the load bus bars with hex head capscrews ring terminals and spring washers Tighten to 10 to 12 ft Ibs 13 6 to 16 3 Nem torque Connect the control wiring leads to the jumper bus bars Contro
152. iliary relays provide contacts for ener gizing external alarms remote indicators and con trol equipment such as louver motors and water pumps Exerciser Clock Option The optional exerciser clock initiates generator set start run cycles at programmable intervals and for programmable durations It is a 7 day 24 hour clock that can store and execute up to ten start stop programs exercise cycles Redistribution or publication of this document by any means is strictly prohibited Y lt Load Shed Option The optional Load Shed function is used to discon nect the load from an available Emergency source in order to reduce the power consumed from that source The Load Shed function when activated by a customer supplied signal moves the transfer switch from the Emergency position to the neutral position Alarm Module Option The optional alarm module provides an audible indi cation that the transfer switch has transferred to the emergency power source Phase Sequence Balance Monitor Option The optional phase sequence balance monitor senses A B and C phases ol utility power If there is an over or undervoltage a phase reversal a loss of one phase or an unbalanced voltage condition a normally energized relay drops out initiating the generator set start transfer of load sequence Standby Set Start Sequencer Option The optional standby set start sequencer is avail able only on a generator set to generator set
153. ing If there is generator voltage at the Emergency lugs of the transfer switch then there is an open in the wiring from the Emergency lugs Phase A and B to the primary side of T2 Unplug P2 while watching K2 Does the relay drop out Either relay K2 on the accessory control panel is defective or there is an open in the wiring from J7 4 to K2 A There may be an open between K2 9 or K2 7 and the linear motor The cir cuit breaker CB1 can be open or defective or the linear motor could be de fective Both are located on the transfer switch wer 3 6 Redistribution or publication of this document ot Y lt Generation by any means is strictly prohibited 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 The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components Improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety precautions in your generator set manuals TROUBLESHOOTING 3 4 Source 2 Voltage Sensor Does Not Sense Voltage This procedure is to be performed with the generator set running When taking voltag
154. ing 12 5 VDC 14 VDC to 19 VDC HI Alarm Factory Setting 14 5 VDC 24 volt charger 18 VDC to 25 VDC LO Alarm Factory Setting 25 VDC 27 VDC to 36 VDC HI Alarm Factory Setting 29 VDC 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 when making ad justments to avoid touching electrical contacts 1 Open the cabinet door 2 Use a small screwdriver to turn the HI Alm or LO Alm adjustment potentiometers on the charger panel counterclockwise to decrease the alarm voltage and clockwise to increase the alarm voltage The graduations on the ad justment potentiometers are approximate 1 volt 3 When finished close and lock the cabinet door When you have finished the adjustments of the optional control modules place the Motor Dis connect Switch on the accessory control panel in the Auto position and close and lock the cabinet door Automatic transfer switch opera tion results in rapid movement of the manual operator handles and presents a hazard of se vere personal injury Keep hands clear of han dles when switching back to automatic opera tion Redistribution or publication of this document by any means is strictly prohibited Power 2 28 Redistribution or publication of this document ion by any means is strictly prohibited 3 Troubleshooting Electronic Control System This section
155. ion Moving the switch to Test sends a start signal to the generator set After the transfer time delay the generator set will assume the load provided Power Generation 1 2 that the Test With Without Load switch Figure 1 3 is in the With Load position Moving the switch to Normal causes the load to transfer to the Normal power source after the re transfer time delay To avoid the delay and cause a fast retransfer of load to the Normal power source move the switch to the Retransfer position Optional Meter Package The optional meter package includes an AC amme ter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltage of the selected power source AC Ammeter The ammeter measures the line cur rents of the load Frequency Meter This meter measures the output frequency of the selected power source in hertz Phase Selector Switch This switch is used to se lect the source and phase to be measured On transfer switches with an AC ammeter the load wires must each pass through a current transform er Optional Auto Manual Switch Utility to Generator Set The Auto Manual switch is used to enable or dis able the automatic retransfer function This switch has two positions In the Auto position normal auto matic retransfer is enabled In the Manual position automatic retransfer from a functioning generator set back to utility power is disa
156. 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 The alarm contacts are rated for 4 amperes at 120 VAC or 30 VDC Connections to these contacts are made at terminals 41 42 43 AC failure 44 45 46 high battery voltage and 47 48 49 low battery voltage of TB3 Figure 2 11 The high and low alarm and float voltage adjust ments are set at the factory Adjustment proce dures are described later in this section Power osi Y lt Generation 2 14 a X t lt WAL e e e DC AMPERES d rav VOLTAGE ADJUSTMENT ES1692 SC1613 2 AMP 10 AMP CHARGER CHARGER FIGURE 2 10 BATTERY CHARGER AC LINE FAILURE LLL LLL BATTERY VOLTAGE LIII SC1578 2 FIGURE 2 11 10 AMPERE BATTERY CHARGER ALARM CONTACTS Redistribution or publication of this document by any means is strictly prohibited w M Auxiliary Relays Optional auxiliary relays Figure 2 12 provide con tacts for energizing external alarms remote indica tors and control equipment such as louver motors and water pumps There are three types of auxiliary relay coils 12 VDC 24 VDC and 24 VAC DC relay coils are powered by B voltage AC relay coils are powered by the 24 VAC outputs of T1 and T2 Al
157. ist Then take the necessary steps to protect per sonnel and the equipment This symbol warns of immediate hazards that will result in 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 AC and DC voltages in the transfer switch compo nents present serious shock hazards that can result in severe personal injury or death Read and follow these instructions Keep the transfer switch cabinet closed and locked Make sure only authorized personnel have the cabi net and operational keys Due to the serious shock hazard from high voltages within the cabinet all service and adjustments to the transfer switch must be performed only by an electrician or authorized service representative Power Generation If the cabinet must be opened for any reason 1 Move the operation selector switch on the gen erator set or Stop Auto Handcrank switch on the automatic transfer switch whichever ap plies to Stop 2 Disconnect the starting batteries of the genera tor set remove the ground lead first 3 Remove AC power to the automatic transfer switch If the instructions require otherwise use extreme caution due to the danger of shock hazard Place rubber insulative mats on dry wood platforms over metal or concrete floors
158. ition the trouble may be in Program Transition module or relay K3 Place the Delay No Delay switch in the No Delay position If transfer occurs replace the Program Transition module If transfer does not occur replace K3 When taking voltage measurements be sure that the probe penetrates the conformal coating on the boards 1 Is Source 2 Available lamp lit Go to the Source 2 voltage sensor troubleshooting section Is the Transfer Timing lamp lit 15 the Transfer Timing Complete lamp on Replace the time delay board Turn the transfer delay potentiometer on the time delay board to mini mum fully counterclockwise If the Transfer Timing Complete lamp does not come on within two minutes then replace the time delay board If the Transfer Timing Complete lamp does come on but the transfer switch still doesn t transfer then go to Step 7 15 the Motor Disconnect switch on the accessory control panel in the Auto position Place the Motor Disconnect switch in the Auto position Does the transfer switch transfer If the optional Signal Module is used check that the ribbon cable from the mother board to the option board is connected properly If the cable is OK then place the Delay No Delay switch on the option board in the No Delay position Does the switch transfer Replace the Signal Module Power Generation 3 5 Redistribution or publication of this document by any means is strictly
159. ition when making adjustments Return the switch to the Auto position after adjustments are completed Three Wire Start The 3 Wire Start module has two adjustable timers The Preheat timer delays the start signal to allow preheating the generator set The Preheat timer s range of adjustment is 0 to 60 seconds If the module has a Preheat On Off switch make sure that it is in the correct position The Overcrank timer limits the time that the genera tor set starter is allowed to operate The Overcrank timer s range of adjustment is 0 to 120 seconds To set the timers align the slots on the potentiome ters with the desired markings on the faceplate Program Transition The Program Transition module has one adjustable timer The Program Transition time delay holds the transfer switch in the neutral position before allow ing it to complete a transfer to the other source This module is available with two adjustment ranges 0 to 7 5 seconds or 0 to 60 seconds To set the time delay align the slot on the poten tiometer with the desired marking on the faceplate If a time delay is desired make sure that the Delay No Delay switch is in the Delay position Signal Module The Signal Module has one adjustable timer The Elevator Signal delay controls the timing of two Redistribution or publication of this document by any means is strictly prohibited events It delays transfer retransfer and energizes the Elevator Transfer Sig
160. l relays have two normally open and two normally closed contacts that are rated for 6 amperes at 600 VAC Table 2 2 is a partial list of the auxiliary relay op tions The AC relays are energized by the same signals that power the corresponding indicator lamps on the cabinet door The Emergency and Normal DC relays are ener gized to indicate transfer switch position The Gen set Run DC relay is energized only when the 2 wire start signal is present at the RMT terminal of TB2 Refer to sheet 1 and to the drawings referenced on sheet 3 of your schematic and wiring diagram pack age Load Shed The optional Load Shed function is used to discon nect the load from an available Emergency source in order to reduce the power consumed from that source The Load Shed function when activated by a customer supplied signal moves the transfer switch from the Emergency position to the neutral position Load Shed signal relay K4 is energized by the clos ing of a switch across terminals TB3 29 and TB3 30 When K4 is energized four sets of K4 con tacts act in conjunction with auxiliary switch S8 and relay K2 to drive the linear actuator and move the transfer switch from the Emergency position to the neutral position When load shedding is in effect a return of Normal utility power will cause retransfer to the Normal power source immediately If the load shed signal is removed before Normal power returns the switch will transfer back to th
161. l wires are marked LOAD A B C for identification Apply thread sealant blue Loctite 242 Onan part number 518 0309 is recommended to the threads of the interlock bar capscrews Install the interlock bar and secure to each interlock arm with a hex head capscrew lock washer and flat washer Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem Place the arc chute covers in position over the arc chutes Attempt to close both sides of the transfer switch The interlock assembly must hold one side open so that only one side closes at at time Replace the linear actuator as described in the Linear Actuator Removal and Replacement section for 800 and 1000 ampere switches Follow steps 2 through 10 in the Replacing Ac tuator section Redistribution or publication of this document by any means is strictly prohibited 18 Test the switch for proper operation and close the cabinet AUXILIARY SWITCH REMOVAL AND REPLACEMENT 800 and 1000 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe per
162. lays including K11 the two wire run relay Connections to the mother board are made through five mating locking pin connectors J4 J5 J6 J7 and J8 and three circuit board edge connectors J1 J2 and J3 There are three different mother boards Utility to generator set transfer switches may be equipped with mother board 300 3953 or mother board 300 3090 Utility to utility and generator set to generator set transfer switches are equipped with mother board 300 3267 Mother board Identification Mother board 300 3090 has one With Without Load switch Moth er board 300 3953 has two With Without Load switches Mother board 300 3267 does not have a With Without Load switch The schematics of the various mother boards appear in Section 8 Significant differences are pointed out in this section J1 J2 and J3 Edge Connectors Connectors J1 and J3 provide a mechanical electrical connection point for the voltage sensor modules Connector J1 corresponds to the Source 1 Normal power source and J3 corresponds to the Source 2 Emer gency power source Connector J2 provides a me chanical electrical connection point for the time delay module Redistribution or publication of this document by any means is strictly prohibited EXERCISE 300 3953 MOTHER BOARD WITH WITHOUT LOAD SELECTOR SWITCH LOCAL TEST X EMERGENCY WITH WITHOUT LOAD SELECTOR VOLTAGE SENSOR SWITCH MODULE NORMAL I 5 B TIME DELAY VOLT
163. lock and con tact assembly to the base and lift off the block and contact assembly Remove the hex head capscrew and lock washer that secure the interlock arm assembly to the block assembly and lift off the interlock arm 11 Redistribution or publication of this document by any means is strictly prohibited INTERLOCK INTERLOCK INTERLOCK 1 ARM BAR ARM BLOCK AND CROSSBAR o Z ASSEMBLY o o Q Qu LOAD C LUG TERMINALS eio QO 96 JUMPER BUS BAR LOAD BUS BAR JUMPER BUS BAR Q TORQUE TO 70 TO 75 IN LBS 7 9 8 5 Nem 2 TORQUE TO 10 TO 12 FT LBS 13 6 TO 16 3 Nem 8 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem SEIS FIGURE 4 13 3 POLE SWITCH ASSEMBLY 300 TO 600 AMPERES Dawer E A 4 21 Redistribution or publication of this document Generation by any means is strictly prohibited INTERLOCK INTERLOCK 2 3 INTERLOCK ARM ARM NEUTRAL BLOCK AND CROSSBAR ASSEMBLY Cm VAT BLOCK AND c CROSSBAR ASSEMBLY e 5 5 T MES Lf LUG sf i I TERMINALS CQ aD BASE GND Lim Bss Pse JUMPER BUS BAR LOAD BUS BAR BUS BAR D TOR
164. lockwise to increase the float voltage Ad just in small steps and wait five minutes for the voltage to stabilize before making additional adjustments AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death Use care when making adjustments to avoid touching electrical contacts When adjustments are complete close and lock the transfer switch cabinet door Disconnect the voltmeter from the battery ter minals and disconnect the test battery nega tive lead first from the generator set Reconnect the generator set starting battery negative lead last and place the operation selector switch in the Auto three wire start or Remote two wire start position Power Generation 2 27 10 Amp Charger Alarm Settings If the battery voltage rises above the HI alarm set ting or drops below the LO alarm setting for 90 sec onds the corresponding HI or LO battery alarm LED is lit and a corresponding optional set of form C relay contacts is activated 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 The high and low alarm adjustments are set at the factory The ranges and factory settings are 12 volt charger 9 VDC to 13 VDC LO Alarm Factory Sett
165. mally closed contacts that are rated for 6 amperes at 600 VAC Figure 7 5 Table 7 1 lists several auxiliary relay options The relays are energized by the same signals that power the corresponding indicator lamps on the SC1576 Ce r FIGURE 7 5 AUXILIARY RELAYS Refer to sheet 1 and to the drawings referenced on sheet 3 of your schematic and wiring diagram pack age Fr Po wer 7 5 Redistribution or publication of this document gt Generation by any means is strictly prohibited Programmed Transition Option The optional Program Transition module Figure Timing 7 6 is used to introduce a pause during transition Programmed transition allows the transfer switch to Delay assume a mid transition position for an adjustable Seconds interval of time In this position the load is nected to either power source This feature allows residual voltage from inductive loads to decay to an acceptable level before transfer is completed The length of time that the transfer switch is in the midposition can be adjusted from 0 to 7 5 seconds or 0 to 60 seconds depending on the timer option Program The proper adjustment is a function of the load Transition To set the time delay align the slot on the poten SC1583 tiometer with the desired marking on the faceplate If a time delay is desired make sure that the Delay No Delay switch is in the Delay position Refer to sheets 2 and 5 of your schemati
166. me When the Stop time is reached press the set button Off Mode is indicated Figure 2 Example to change over the genset at 7 00 PM Set Start at 7 00 PM 19 00 Set Stop at 7 05 PM 19 05 Note that the change over time is indicated by a segment illuminated around the outer ring of the clock from the start to the stop time Figure 2 Note also that the genset will start and con tinue to run after the five minute ON time ex pires until the next program ON time To clear the program press the plus and set 4 buttons at the same time Pressing the arrow button advances to the next day The program will be copied to the next day if the next day does not have an existing program To change or clear the program press the plus and set buttons at the same time Double check the program setting for each day Press the arrow button repeatedly until the clock mode is passed and the pro gram mode Pr is reached Carefully check each days program and clear any unwanted programs When finished programming press the arrow 7 button until the clock appears in the upper left corner of the display Power Generation During the change over period the ON mode is in dicated in the ellipse in the upper right corner of the display Figure 2 To Check The Programs Push the arrow button to review each setting To Erase Clear A Program Press the arrow button until the pro
167. ment is 0 to 120 seconds To set the timers align the slots on the potentiome ters with the desired markings on the faceplate Fig ure 5 6 The Auto Stop Handcrank Switch is located on the 3 Wire Start module This switch is the operation selector switch for a three wire start generator set The three positions Auto Stop and Handcrank function as follows Auto Allows the generator set to start and assume the load if a power outage oc curs This is the normal operating position Shuts down the generator set and prevents it from starting Use this position when servicing the gener ator set Prevents the automatic transfer switch from starting the generator set but allows starting and stopping at the set Use this position for generator set maintenance The three wire start circuit uses TB3 terminals 1 2 3 4 and 5 for unit 2 and terminals 31 32 33 34 and 35 for unit 1 See Figure 5 7 TB3 terminals 1 2 3 and 4 are connected to termi nals on the source 2 generator set as shown in Fig ure 5 7 With diesel sets that use the preheat cir cuit terminal 5 on TB3 is connected to terminal H on the source 2 generator set control terminals 31 32 33 and 34 are connected to terminals on the source 1 generator set as shown in Figure 5 7 With diesel sets that use the preheat cir cuit terminal 35 on TB3 is connected to terminal H on the source 1 generator set control TB3 terminals 6 7 and 8 unit
168. move wire ties as re quired Redistribution or publication of this document by any means is strictly prohibited ACTUATOR ROD LINEAR ACTUATOR lzmaozmam gt r lt ROD END 4 ASSEMBLY C9 eee ere T rosAazoo TERMINAL BRACKET EMERGENCY A B C GROUND CONNECTION 1 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem 2 TORQUE TO 70 TO 75 IN LBS 7 9 TO 8 5 Nem SC1569s FIGURE 4 1 TRANSFER SWITCH COVER 40 TO125 AMPERES Pow v r 4 2 Redistribution or publication of this document Generation by any means is strictly prohibited Pry the capacitor s loose from the bracket Re move the end cap and disconnect the red and white actuator leads from the capacitor and the black lead from circuit breaker Note the lead connections to the capacitor terminals Remove the socket head capscrews and lock washers that secure the actuator to the block assemblies Figure 4 1 Note the ground wire connection to the lower left capscrew Disengage the actuator rod from the switch handle and remove the actuator from the block assembly Remove one of the hex head capscrews and lock washers that secure the rod end assembly to the actuator rod Remove the rod end assembly from the actu
169. nal relay during the delay period This time delay is adjustable over a range of 0 to 50 seconds ES voip To set the time delay align the slot on the poten tiometer with the desired marking on the faceplate If a time delay is desired make sure that the Delay No Delay switch is in the Delay position Exerciser Clock The exerciser clock initiates generator set start run cycles at programmable intervals and for program mable durations It is a 7 day 24 hour clock that can store and execute up to ten start stop programs ex ercise cycles FIGURE 2 15 EXERCISER CLOCK SC1579 3 Programming the exerciser clock requires setting the time of day and entering the exercise start and stop times Refer to the circled numbers in Figure 2 15 when reading the following instructions To set the time of day 1 If you are performing installation and setup press the R button 9 with the tip of a ball point pen to reset all memory Do not press the R button if you are only changing the time of day 2 Press the clock button 1 3 Press the h button 3 to set the hour of the day The clock uses 24 hour military time 4 Press the m button 4 to set the minutes of the hour 5 Press the 1 7 button 5 to advance the indica tor bar over the desired day number Use the 1 to represent Sunday 6 Press the Pr button 8 to enter the time To set the exercise start time 1 Slide the output selector switch
170. nd of the actuator rod 9 Remove the rod end assembly Figure 4 11 and slide the actuator rod out of the actuator motor Replacing Actuator 1 Insert the actuator rod into the replacement ac tuator motor Figure 4 12 Hold the actuator ground brush up slightly to allow passage of the actuator rod Install the rod end assembly and tighten the capscrew to 70 to 75 in lbs 7 9 to 8 5 Nem 2 Hold the actuator motor in position over the switch assemblies so the lead wires are at the bottom and fit the rod assembly into the handle of the closed switch assembly 3 Secure the actuator motor to the switch assem blies using hex head capscrews 4 lock wash ers 4 flat washers 8 and spacers 4 Tight en capscrews to 25 to 27 in lbs 2 8 to 3 0 Nem 4 Connect the black actuator lead wire to the cir cuit breaker and the red and white actuator lead wires to the following capacitor terminals White Lead Wire If one capacitor connect to C1 Terminal 2 If two capacitors connect to C2 Terminal 2 Red Lead Wire Connect to C1 Terminal 1 Transfer switches for voltage ranges 347 380 416 and 440 480 use two capacitors C1 and C2 wired together in series A single jumper wire is placed between terminal 2 on C1 and ter minal 1 on C2 5 Replace the capacitor end cap s and install the capacitor s in the bracket s 6 Connect the ground wire to the end of the ac tuator Use wire ties to hold the actuator l
171. nnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components TROUBLESHOOTING 3 1 Continued Transfer Switch Does Not Retransfer When Normal Voltage Returns After A Power Outage This procedure is to be performed with the generator set running and Normal voltage on line 12 If the Signal Module is used check that the ribbon cable from J4 on the mother board to the Signal Module is connected properly If the cable is OK then place the Delay No Delay switch on the Signal Module in the No Delay position Does the transfer switch retransfer Replace the Signal Module Place the elevator signal Delay No Delay switch back in the Delay posi tion Go to Step 15 15 there approximately 24 between J7 6 on the mother board and ground 15 there approximately 24 between J7 7 on the mother board and ground Replace the mother board and recalibrate the voltage sensors 15 there approximately 24 between TI X1 and TI X2 on the accesso ry control panel Either switch S3 on the transfer switch is defective or there is an open in the wiring from T1 X1 to J7 7 on the mother board Is the correct line voltage present on the primary side of T1 on the acces sory control panel Either the connection at transformer T1
172. nued Generator Set Does not Crank for a Power Failure Test or Exercise Using a Switching Ground Three Wire Starting System This procedure is to be performed with the line voltage available and the Test Normal Retransfer switch in the Test position 14 15 16 17 18 19 20 21 22 23 24 Press and release the Overcrank Reset button Does the Preheat lamp light After the preheat time delay does the Overcrank Timing lamp light Does the generator set crank If the generator set cranks but does not start there is a generator set problem Is there 0 VDC at TB3 4 There is a generator set problem There is an open between TB3 4 and J11 8 or the 3 WireStart module is bad Is there 9 to 12 VDC between the anode of CR2 on the mother board and ground There is a bad connection in the ribbon cable between the mother board and the 3 Wire Start module The 3 Wire Start module is bad and must be replaced Replace the mother board and recalibrate the voltage sensors Power 3 10 Generation Redistribution or publication of this document by any means is strictly prohibited X gt Oo 4 w 4 Transfer Switch Assembly GENERAL This section covers the removal and replacement procedures for the transfer switch assembly There are four separate switch assemblies Each assem bly corresponds to a particular ampere range The four ampere range groups are 40 70 100 125 am peres 150 225
173. nute or day 4 Press the Pr button 8 to enter the edited pro gram and return to the time of day display To erase clear a program 1 Press the Ch button 6 until the program to be erased is displayed 2 Press the C button 10 with a ball point pen to clear the program 3 Press the Pr button 8 to return to the time of day display Battery Charger Float Voltage The float voltage is set at the correct value at the factory and should not require adjustment Howev er if the battery shows signs of being overcharged or undercharged the float voltage can be adjusted A high specific gravity bubbling of electrolyte and loss of water indicate a high float voltage A low specific gravity indicates a low float voltage Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any spark arc or flame while servicing batteries To change the float voltage a fully charged battery a hydrometer a small screwdriver and an accurate voltmeter 0 596 accuracy are needed Use the fol lowing procedures to adjust the float voltage Attempting to adjust or test the bat tery charger with a deeply discharged battery can lead to the false conclusion that the charger is malfunctioning Always use a fresh fully charged battery when adjusting or testing the charger Always disconnect the battery char ger from its AC source remove the charger s AC input fuses before disconnecting the bat
174. o Timing lamps a Lockout Lamp a Reset Switch and a Auto Stop Handcrank Switch Figure 5 6 The 3 Wire Start module may be equipped with a preheat timer On Off switch Overcrank occurs when the generator set does not start within the adjustable time limit In order to pro tect the starter motor overcrank relay contacts open the starting circuit and light the Lockout lamp After a starting problem is corrected pressing the Overcrank Reset switch resets the circuit Refer to the Operation Section A set of overcrank alarm contacts are also provided The contacts can be used to energize an external overcrank alarm The 3 Wire Start module has two adjustable timers The Preheat timer delays the start signal to allow preheating the generator set The Preheat timer s range of adjustment is 0 to 60 seconds If the module has a Preheat On Off switch make sure that it is in the correct position Power Generation 5 8 SC 1575 7s FIGURE 5 5 TWO WIRE START CONNECTIONS 3 Wire Start Auto Handcrank Stop 10 Timing Off On Delay Seconds Timing Delay Seconds 120 Lockout 6 Overcrank Reset 5 1573 25 FIGURE 5 6 THREE WIRE START MODULE Redistribution or publication of this document by any means is strictly prohibited gt w The Overcrank timer limits the time that the genera tor set starter is allowed to operate The Overcrank timer s range of adjust
175. on the acces sory control panel enables and disables the linear Power Generation actuator Place the switch in the Auto position to en able the linear actuator Place the switch in the Off position to disable the linear actuator Auxiliary Contacts Auxiliary contacts are provided on the Normal and source 1 and Emergency source 2 sides of the transfer switch They are actuated by operation of the transfer switch during transfer and retransfer The Normal side auxiliary contact switch is actuated when the transfer switch is in the Normal position The Emergency side auxiliary contact switch is ac tuated when the transfer switch is in the Emergency position The auxiliary contacts have current rat ings of 10 amperes at 250 VAC Connections for the auxiliary contacts are made on terminal block TB1 Refer to sheet 1 of your schematic and wiring dia gram package 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 Power Sentry calibration and adjustment proce dures are described in section 2 The most important component of the electronic control system is the Power Sentry control Figure 6 3 The Po
176. onnected to the transformer at a time Refer to sheets 2 and 4 of your schematics and wir ing diagram package Alarm Module Option The optional alarm module Figure 2 13 provides an audible indication that the transfer switch has transferred to the emergency power source A push button on the alarm module provides a means to silence the horn The Alarm lamp indicates that the transfer switch is in the Emergency Connected position If the horn is silenced the Horn Silenced lamp will also light Both lamps will stay lit until the transfer switch moves from the Emergency Connected position to the disconnected neutral or Normal Connected position O Push To Stlence orn 300 3998 FIGURE 2 13 ALARM MODULE Power Generation Redistribution or publication of this document by any means is strictly prohibited CONTROL SYSTEM OPERATION The following text covers the operation of the elec tronic control system in a utility to generator set installation Source 1 is designated as the normal power source and Source 2 is designated as the emergency power source The following situations and control responses are described Normal Power Source Connected to Load e Normal Power Source Interrupted Emergency Power Source Connected to Load Normal Power Source Restored e Test Exercise With Without Load Mother Board 300 3090 Test Exercise With Without Load Mother Board 300 3953 Some of the control comman
177. ons to the auxiliary relays are made direct ly to the relay terminals The terminals accept wire SEITE sizes from one 18 AWG wire to two 12 AWG wires FIGURE 6 6 AUXILIARY RELAYS Table 6 1 lists several auxiliary relay options All relays have two normally open and two normally closed contacts that are rated for 6 amperes at 600 VAC Figure 6 6 The AC relays are energized by the same signals that power the corresponding indicator lamps on the cabinet door Refer to sheet 1 and to the drawings referenced on sheet 3 of your schematic and wiring diagram pack age Alarm Module Option The optional alarm module Figure 6 7 provides an audible indication that the transfer switch has trans ferred to the source 2 power source A push button on the alarm module provides a means to silence the horn The Alarm lamp indicates that the transfer switch is in the Source 2 Connected position If the horn is silenced the Horn Silenced lamp will also light Stienesa Both lamps will stay lit until the transfer switch moves from the Source 2 Connected position to the 300 3998 disconnected neutral or Source 1 Connected position FIGURE 6 7 ALARM MODULE Power 6 7 Redistribution or publication of this document Oo Generation by any means is strictly prohibited X 1 Y lt Automatic Operation The automatic transfer switch is set for automatic operation by placing control switches in the
178. oor The Source 1 Available and Source 2 Available lamps are lit whenever their corresponding power sources are producing power These two lamps can be lit simultaneously The Source 1 Connected and Source 2 Connected lamps indicate which power source is connected to the load Only one of these two lamps can be lit SOURCE 1 CONNECTED LAMP SOURCE 1 AVAILABLE LAMP Onon Transfer Switch PHASE SELECTOR SWITCH FOR OPTIONAL METERS Source Selector Switch This is a three position switch In the Auto position the optional change over clock determines which generator set has priority to run and assume load Transfer and retransfer are con trolled by the change over clock and in the event of a generator set fault the voltage sensing and timing components of the electronic control system In the Source 1 position the source 1 generator set has priority to run and assume load The load re mains connected to source 1 unless a source 1 fail ure is sensed In the Source 2 position the source 2 generator set has priority to run and assume load The load re mains connected to source 2 unless a source 2 fail ure is sensed SOURCE 2 CONNECTED LAMP SOURCE 2 AVAILABLE LAMP OPTIONAL AC VOLTMETER OPTIONAL AC AMMETER OPTIONAL FREQUENCY METER SOURCE SELECTOR SWITCH 1694 35 FIGURE 5 2 GENERATOR SET TO GENERATOR SET TRANSFER SWITCH CABINET WITH OPTIONS Generation Power gt
179. ored for an overvoltage condition As with the standard undervoltage sensing the volt age sensors signal the time delay module which controls the transfer or retransfer sequence An adjustable time delay overrides momentary overshoots in voltage Frequency Sensing With optional frequency sensing the Normal and Emergency sources are monitored for variations in frequency The sensors detect whether or not the source is within an adjust able bandwidth As with the standard undervoltage sensing the fre quency sensors signal the time delay module which controls the transfer or retransfer sequence An adjustable time delay allows the control to ignore momentary dips or rises in frequency 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 signals the generator set to start An open switch signals the electric generator set to stop Three Wire Starting Option The optional three wire starting control available only on 40 to 125 ampere units enables the trans fer switch to start and stop a three wire start genera tor set Three wire starting logic is similar to a Power Generation single pole double throw switch A common is closed to one side to send a start signal
180. ough connector J1 P1 on the accessory control panel and through the phase selector switch S13 On switches rated for more than 300 VAC transformer T3 is used be tween S13 and the meters to step down the voltage Power to the ammeter is supplied from current transformers through switch S13 and directly to the ammeter Cables from the source are passed once through the current transformers Refer to sheets 2 and 5 of your schematic and wir ing diagram package Auto Manual Switch The optional Auto Manual switch is used to enable or disable the automatic retransfer function This switch has two positions In the Auto position nor mal automatic retransfer is enabled In the Manual position automatic retransfer is disabled only manually initiated retransfer is possible Horn Stlenced In the Manual position the switch closes and pro vides a ground at J7 3 on the Power Sentry mother board This signal is optically coupled to the time delay module where it overrides the automatic re transfer timer Refer to the Power Sentry mother board schematic Section 8 and to sheet 3 of your schematic and wiring diagram package 600 VAC Adapter Transformer On 600 VAC switches transformer T4 is connected between phase A and B sources and the linear ac tuator to step down the AC voltage A special pair of interposing relays K1 and K2 equipped with a me chanical interlock allow only one source Normal or Emergency to be c
181. over Retransfer Time Delay This delay begins when the preferred source voltage and frequency return After the delay the transfer switch can retransfer the load to the preferred source The delay allows the preferred source to stabilize before retransfer It has an adjustable range of 0 to 30 minutes To set this time delay align the slot on the poten tiometer with the desired marking on the Power Sentry cover Undervoltage Sensing Two voltage sensors one for the source 1 side and one for the source 2 side monitor source voltages for an undervoltage condition and generate signals which are sent to the time delay module If for ex ample an undervoltage condition is sensed on the priority source the voltage sensor module sends a signal to the time delay module that initiates and controls the transfer of load The standard transfer switch has undervoltage sensing for all phases of the source 1 and source 2 power sources Undervoltage adjustment and calibration proce dures are described in section 2 Power Generation 6 5 Overvoltage and Frequency Sensing Option Overvoltage and frequency sensing are available as a single option Overvoltage Sensing With optional overvoltage sensing the source 1 and source 2 power sources are monitored for an overvoltage condition As with the standard undervoltage sensing the volt age sensors signal the time delay module which controls the transfer or retransfer sequen
182. pecial See Production Order 50 Hz N 240 120 Volt S 240 120 Volt T 380 220 Volt 1 Phase 3 Wire 3 Phase 4 Wire 3 Phase 4 Wire R Special See Production Order 6 Sequentially assigned spec number issued for each specific combination of accessories 7 Specification letter advances with production modification Redistribution or publication of this document by any means is strictly prohibited Ga FEATURE FEATURE DESCRIPTION OPTION Poles Poles A028 Poles uuu ev eU A029 Application Appl Utility to Genset A035 Appl Utility to Utility A036 Appl Genset to Genset A037 Appl Nonautomatic A038 Agency Approvals Listing UL A046 Certification CSA A047 Listing Not Applicable A048 Frequency 60 044 OO HONZ x ocrec er reet A045 Voltage 208 VAG u quas sya sas PED R021 220 R022 qa R023 80 R024 416 VAC R025 480 VAC R026 600 VAG rannan tace quya R027 Phase System 1 Phase 2 W or 3 W A041 System 3 Phase 3 W or 4 W A042 Control Options Start Time Delay 90 Sec C015 Control OV amp O U Hz Source 2 C016
183. perational reliability of the transfer switch 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 In addition incorrect installation service or parts re placement can result in severe personal injury death and or equipment damage Therefore all cor rective service procedures must only be performed by technically qualified personnel following the procedures provided in this manual The transfer switch presents a shock hazard that can cause severe personal injury or death unless all AC power is removed Be sure to move the generator set operation selector switch to Stop disconnect AC line power disconnect the battery charger from its AC power source and discon nect the starting battery negative lead first before servicing AWARNING gnition of explosive battery gases can cause severe personal injury Do not smoke or cause any spark arc or flame while servicing batteries TABLE 1 1 ANNUAL PREVENTIVE MAINTENANCE 1 DISCONNECT ALL SOURCES OF AC POWER Disconnect both AC power sources from the transfer switch before continuing If a generator set pro vides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel f there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first 2 CLEAN a T
184. posi tions given below Motor Disconnect Switch Auto position Source selector switch Source 1 or Source 2 Manual Operation The transfer switch has operator handles for manu ally transferring the load Use the following proce dure 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 If possible remove all AC power to the transfer switch before manually operating the switch If it is necessary to perform manual operation with AC power connected follow the Safety Related Work Practices listed in NFPA 70E 1 Open the cabinet door of the automatic transfer switch 2 Move the Motor Disconnect switch to the Off position 3 Transfer from the Normal to the Emergen cy power source A Pull the upper manual operator handle down B Push the lower manual operator handle down Retransfer from the Emergency to the Nor mal power source C Pull the lower manual operator handle up D Push the upper manual operator handle up 4 Before moving the Motor Disconnect switch back to the Auto position remember the trans fer switch will transfer load to the active power source if both power sources are available it will transfer the load to the preferred source Power Generation 6 8 Automatic transfer switch op eration results in
185. publication of this document by any means is strictly prohibited SIDE WITH TWO TERMINALS SWITCH LEVER IN CLOSED POSITION NORMAL SIDE EMERGENCY SIDE INSULATING BARRIERS ToT Gig BRACKETS A D TORQUE TO 10 TO 15 IN LBS 1 1 TO 1 7 Nem Q V Ger FIGURE 4 5 AUXILIARY SWITCHES 40 TO 125 AMPERES SC1557s 4 8 Redistribution or publication of this document neration by any means is strictly prohibited 2 gt LINEAR ACTUATOR REMOVAL AND REPLACEMENT 150 to 260 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the linear actuator for 150 to 260 am pere switches Removing Actuator 1 Open the transfer switch cabinet door 2 Loosen and remove the two self locking nuts and the two machine screws with flat washers that secure the plastic switch cover to th
186. r and nut Tight en to 25 to 30 in lbs 2 8 to 3 4 Nem torque 9 Connect the control wiring leads to the corre sponding jumper bus bar terminal Control wires are marked LOAD A B C for identifica tion Redistribution or publication of this document by any means is strictly prohibited INTERLOCK LOAD BUS BAR BARS 1 I l JUMPER BUS BAR 1 JUMPER BUS BAR LOAD BUS BAR VIEW D D D TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem TORQUE TO 15 TO 20 IN LBS 1 7 TO 2 3 Nem SC1566s FIGURE 4 3 SWITCH ASSEMBLY 40 TO 125 AMPERES Dower 1 w 2 uis 4 5 Redistribution or publication of this document r x tr o L Le Generation by any means is strictly prohibited d 10 11 POWER SOURCE LEAD TERMINAL CONTROL WIRING TERMINAL SC1556s FIGURE 4 4 CONTROL WIRING TERMINALS 40 TO 125 AMPERES Apply thread sealant blue Loctite 242 Onan part number 518 0309 is recommended to the threads of the interlock bar machine screws Install the interlock bar and secure to each in terlock arm with a round head machine screw and flat washer Tighten to 15 to 20 1 7 to 2 3 Nem torque Attempt to close both sides of the transfer switch
187. r Connect Bus Stabs N009 Cabinet Cabinet Type 1 B001 Cabinet B002 Cabinet Type 4 B003 Open Construction B004 Redistribution or publication of this document by any means is strictly prohibited Power 1 12 Redistribution or publication of this document ion by any means is strictly prohibited 2 Electronic Control System INTRODUCTION The electronic control system includes 1 The voltage sensing and start stop transfer and retransfer timing circuitry of the Power Sentry control 2 The transformers relays switch and connec tors of the accessory control panel 3 The optional control modules and accessories 4 The position sensing switches that monitor and control the operation of the automatic transfer switch 5 The standard and optional lamps meters and switches that are mounted on the cabinet door These components are described in Section 1 They are also referenced in this section when applicable POWER SENTRY CONTROL The Power Sentry control Figure 2 1 consists of the following major components e Transformer assembly Mother board e Voltage sensor modules e Time delay module All components of the Power Sentry control are mounted within a single enclosure The timing sensitivity and calibration potentiome ters and LED control lamps are visible and accessi ble through holes on the cont
188. r switch before servicing The following procedures cover the removal and re placement of the block and cross bar assemblies for 800 and 1000 ampere switches Removing the Block and Cross bar Assembly Normal or Emergency 1 Remove the linear actuator as described in the Linear Actuator Removal and Replacement section for 800 and 1000 ampere switches 2 Lift the arc chute covers off the arc chutes 3 Remove the hex head capscrews lock wash ers and flat washers that secure the interlock bar to the interlock arm Figures 4 18 and 4 19 and remove the interlock bar 4 Disconnect the control wiring leads from the jumper bus bars 5 Remove the hex head capscrews ring termi nals and spring washers that secure the jumper bus bars Figures 4 18 and 4 19 to the load bus bars 6 Remove the hex head capscrews spring washers and bushings that secure the jumper bus bars to the switch assemblies Lift off the jumper bus bars The neutral pole on the 4 pole switches does not have a bushing at this connection 7 Remove the control wiring leads from the pow er source terminals 8 Loosen the lug terminal screws and remove the power source supply wires from the lug termi nals 9 With a screwdriver dig the glue out of the insu lator cups that cover and insulate the block as sembly mounting screws Power Generation 4 28 10 Remove the hex head capscrews and flat washers that secure the block assemblies
189. r switch is in the midposition can be adjusted from 0 to 7 5 seconds or 0 to 60 seconds depending on the timer option The proper adjustment is a function of the load To set the time delay align the slot on the poten tiometer with the desired marking on the faceplate Figure 6 4 If a time delay is desired make sure that the Delay No Delay switch is in the Delay position Refer to sheets 2 and 5 of your schematic and wir ing diagram package Signal Module Option The optional Signal Module Figure 6 5 has one adjustable timer The Elevator Signal delay con trols the timing of two events It delays transfer re transfer and energizes the Elevator Transfer Signal relay during the delay period This time delay is ad justable over a range of 0 to 50 seconds A Delay No Delay switch permits bypassing the tim er delay if itis not needed The timing circuit is started by a transfer or a retran sfer signal from the time delay module on the Power Sentry mother board While the timer is timing the form C Elevator Sig nal relay is energized and the Timing lamp on the Signal Module is lit At the end of the time delay the Elevator Signal relay is de energized and the switch is allowed to transfer or retransfer There are three other relays with form C contacts on the Signal Module Source 1 Available Source 2 Available Backup Source Available These relays are not affected by the Elevator Signal delay They re
190. raming mode is reached Pr will be flashing if there are no existing programs Press the arrow button as many times as necessary to advance to the day to be pro grammed To clear an existing program for the day se lected press the plus and set B buttons at the same time 3 Press the plus button to increment the Start time of the exercise program The display will show midnight 0 00 Note that by holding the button down the minutes will increment in 15 minute intervals When the Start time is reached press the button On Mode is indicated Figure 2 Then increment the time with the plus but ton to the desired Stop time When the Stop time is reached press the set button Off Mode is indicated Figure 2 Example to exercise the genset one hour Set Start at 7 00 PM 19 00 Set Stop at 8 00 PM 20 00 TEMPORARY OVERRIDE MODE Note that the exercise time is indicated by a FLASHING HANDS INDICATES band of segments illuminated around the outer a ONORE VORE ON MODE ring of the clock from the start to the stop time Figure 2 To clear the program press the plus and set buttons at the same time 4 Pressing the arrow button advances to the next day The program will be copied to the next day if the next day does not have an existing program To change or clear the program press the plus and set buttons at the s
191. rce 2 available relay is energized only when the source 2 sensor determines that Emer gency power is acceptable The opening of K12 contacts 4 and 2 in conjunction with test or exercise with load signals helps simulate a loss of Normal power for test and exercise purposes If Emergen cy power fails during a test or exercise the closing of these contacts initiates retransfer to the Normal power source The K12 relay is included only on the utility to gener ator set mother board On the 300 3090 mother board the K13 test exer cise relay is energized by a signal at one of the test exercise inputs When K13 is energized its con tacts 3 and 2 open This action de energizes K11 starting the generator set On the 300 3953 mother board the K13 test exer cise relay is energized by a signal at one of the test exercise inputs only when the corresponding With Without Load switch is in the Without Load position When K13 is energized its contacts 3 and 2 open This action de energizes K11 starting the genera tor set The K13 relay is included only on the utility to gener ator set mother board The K14 and K15 transfer and retransfer relays are energized by signals from the time delay module When energized their contacts 3 and 4 close to pro vide power to one of the interposing relays K14 drives the K2 transfer relay K15 drives the K1 re Power Generation 2 4 transfer relay K1 and K2 are located on the acces sory
192. res are described in Section 4 Contact Assemblies The transfer switch either has three or four poles Three pole transfer switches are provided with a neutral bar The contact assemblies make and break the current flow When closed to either the Normal or the Emergency power source the con tacts are mechanically held A mechanical interlock prevents them from closing to both power sources at the same time Linear Actuator The linear actuator is a linear induction motor that moves the contact assemblies between the Normal power source and the Emergency power source Linear actuator operation is initiated automatically with automatic transfer switches Manual operation of the transfer switch is also possible Refer to Manual Operation Capacitor s Either one or two capacitors refer to Section 4 pro vide the phase shift necessary to drive the linear motor If the capacitor is faulty the linear motor does not operate Motor Disconnect Switch The Motor Disconnect toggle switch on the acces sory control panel enables and disables the linear actuator circuit Place the switch in the Auto posi tion to enable the linear actuator Place the switch in the Off position to disable the linear actuator Auxiliary Switches Eight auxiliary switches are configured to respond to the position of the transfer switch When the transfer switch is in the Normal position switches S2 S3 94 and S5 are actuated When the transfer swit
193. retransfer the switch see Opera tion Redistribution or publication of this document by any means is strictly prohibited 8 Schematics SCHEMATIC PAGE Mother Board 300 3953 Utility to Generator Set 8 3 Mother Board 300 3267 Utility to Utility sss 8 4 Mother Board 300 3090 Utility to Generator Set 8 5 picco cM PPP 8 6 626 1762 Sheet MT TT 8 7 626 1762 Sheet 3 015 ilia hp send da ads den d 8 8 626 1762 Sheet 4 RETE RE ERE RE RSS 8 9 626 1762 Sheet 5 OT B cus dx RERO shana Cama 8 10 FA Power 8 1 Redistribution or publication of this document o Generation by any means is strictly prohibited im Power 8 2 Redistribution or publication of this document ion by any means is strictly prohibited START JZ S 17 7 TO SOURCE TO SOURCE GENSET 3 3 ONE TWO TRANSFER RETRANSFER CONNECTED CONNECTED CONTACT K14 3 CONTACT K15 3 LIGHT LIGHT F F J 4 37 6 GND OR B J8 6 lt BATTERY TRANSFER INHIBIT Acre 28 2 J8 1 LOAD 76 12 LOAD K12 2 K10 2 4 N 4 CR30 lt lt EE J6 1 POWER SIGNAL MOD POWER 2 3 WIRE J6 11 INSTANT RETRANSFER MANUAL RETE RETRANS TEST TEST TEST
194. rform these steps in the following sequence Replace the ribbon cable If source 2 voltage is not sensed replace the transformer assembly and recalibrate the voltage sensors If source 2 voltage is not sensed replace the mother board and recali brate the voltage sensors Power 3 7 Redistribution or publication of this document Generation by any means is strictly prohibited 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 The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components Improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety precautions in your generator set manuals Ignition of explosive battery gases can cause severe personal injury or death Do not smoke or cause any spark or flame while servicing batteries TROUBLESHOOTING 3 5 Generator Does not Crank for a Power Failure Test or Exercise Using a Two Wire Starting System This procedure is to be performed with the Normal voltage available and the Test Nor mal Retransfer switch in the Test position When taking voltage measurements be sure that the prob
195. rgize that relay When K18 is energized its normally closed contacts open When contacts K18 2 K18 4 open Normal phase A B power to the bridge rectifier is cut off and a simulated power failure is sensed With Normal phase A B power to the Normal side voltage sensor interrupted generator set start tim ing begins When the generator set starts and the source 2 voltage sensor senses generator set volt age transfer of load timing begins After the trans fer timer times out the time delay module sends a signal to relay K14 and transfer of load occurs When the transfer switch is in the Emergency posi tion and the Emergency source is energized K16 is energized by the action of position sensing auxil iary switch S7 When K16 is energized its run inter lock contacts K16 2 K16 4 are open preventing K11 from being re energized This prevents the control from stopping the generator set as long as it is still powering the load Power Generation As the generator set runs and produces power at an acceptable voltage and frequency the Source 2 Available lamp lights and the source 2 available relay K12 is energized opening contacts K12 2 K12 4 If the generator set fails during test or exercise these contacts close to initiate retransfer to Normal power Note that with the transfer switch in the Emergency position contacts K10 2 K10 4 are closed End of Test Exercise The test exercise period is stopped by removin
196. ring this delay Bl reet ond The overcrank timer limits the time the engine start Overcrank 0 189 motor is engaged If the generator set does Reset Lockout start within the adjustable time limit 0 to 120 sec onds a relay opens the starting circuit During cranking the Overcrank Timing lamp is on If the overcrank timer opens the circuit a Lockout lamp is FIGURE 2 4 3 WIRE START lit After a starting problem is corrected press the Overcrank Reset switch to reset the timer It cannot be reset by any other method The Auto Handcrank Stop switch has three posi tions that function as follows 5 1573 25 Auto Allows the generator set to start and assume the load if a power outage oc curs This is the normal operating position Stop Shuts down the generator set and prevents it from starting Use this position when servicing the gener ator set Handcrank Prevents the automatic transfer switch from starting the generator set but allows starting and stopping at the set Use this position for generator set maintenance Connections for the optional 3 Wire Start module are made at TB3 Generator set to generator set transfer switches can be equipped with two 3 Wire Start modules Refer to section 5 Refer to sheets 1 and 5 of your schematic and wir ing diagram package gt GA Pow er 2 9 Redistribution or publication of this document o 4 Generation by any means is strictly prohibi
197. rol cover Figure 2 1 The following text provides a general description of each component and how it functions Transformer Assembly The transformer assembly is mounted in the control as shown in Figure 2 1 The assembly includes four transformers a terminal block and a ribbon cable connector The transformers step down the line voltage to approximately 18 VAC The output from the transformers is supplied to the mother board rectifier bridges The transformer assemblies are not the same for every control even though they may appear identi cal Each transformer assembly must be used with the correct line voltage and phase or the control can be damaged when power is applied For this rea Power Generation son the transformer assemblies from different con trols are not necessarily interchangeable When replacing a transformer assembly note that the transformer input leads are wired with a line to line or line to neutral configuration and with jumper wires across some of the TB11 terminals The wir ing and jumper wire configurations are voltage and phase dependent Refer to sheet 3 of 5 in your schematic and wiring diagram package Mother Board Assembly The mother board assembly is a printed circuit board that serves as a central terminal for all the in put and output signals that flow through the control It also provides a mounting point for the voltage sensing and time delay modules and several con trol re
198. rque 13 Attempt to close both sides of the transfer switch The interlock assembly must hold one side open so that only one side closes at a time 14 Replace the linear actuator as described in the Linear Actuator Removal and Replacement section for 150 to 260 ampere switches Fol low steps 2 through 9 in the Replacing Actuator section 15 Install the power source supply wires and se curely tighten the lug terminals to the torque value specified on the plastic cover 16 Test the switch for proper operation and close the cabinet AUXILIARY SWITCH REMOVAL AND REPLACEMENT 150 to 260 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing Redistribution or publication of this document by any means is strictly prohibited The following procedures cover the removal and re placement of the auxiliary switch assembly for 150 to 260 ampere switches Removing Auxiliary Switch Assembly 1 Aft
199. rvoltage adjustment range is 105 to 13596 of the nominal voltage The pickup point is fixed at 596 below the overvoltage limit point and is not ad justable A time delay is also included and is adjust able from 0 to 120 seconds Over underfrequency sensing is accomplished by sensing the source frequency and detecting when it is within a specific band The pickup bandwidth is adjusted with a potentiometer refer to Adjusting Power Sentry Modules in this section The pickup adjustment range is 5 to 20 of the nominal fre quency The dropout bandwidth is fixed at 596 wider than the pickup band The pickup and dropout bands are centered about the nominal frequency A time delay is also included and is adjustable from 0 to 15 seconds Time Delay Module The time delay module plugs into the J2 edge con nector on the mother board The time delay module contains the timing circuits and associated logic that provide time delays for generator starting load transfer load retransfer and generator stopping The Source Available output signals are received from the voltage sensors If the Source 1 Available signal is interrupted the start time delay begins tim ing out The start time delay adjustable from 0 to 15 sec onds begins timing if the input signal from the Source 1 voltage sensor is interrupted If the signal returns during the timing out period the timer is re set If the signal does not return by the end of the delay period
200. s an alternative use Table 1 NFPA 20 requires any upstream overcurrent pro tective device fuse or circuit breaker on the utility source side to be sized to carry fire pump locked ro tor current continuously As a result this upstream overcurrent protective device OCD may be signifi cantly oversized Verify that the upstream OCD on the utility source side is within the the maximum ampere rating al lowed for withstand and closing rating WCR of the ATS If it is not oversize the ATS as necessary Location The ATS and emergency side isolating switch must be located in the fire pump room Isolating Switch The contractor must furnish and install a lockable isolating switch with auxiliary contacts on the gen erator side of the ATS See Figure 1 Power Generation TABLE 1 ATS SIZING FOR FIRE PUMP MOTORS Motor HP Rated Amps Rated Amps pou we po pc p ue WE C NNNM M posco ues 22 Wa J mE C E ce a Current Three Phase AC Motors Supervision The isolating switch auxiliary contacts must be con nected to the ATS controls to prevent generator set starting when the isolating switch is open Refer to the site interconnection drawing Marking The generator side isolating switch must be marked with a caution that prior to servicing both the gen erator side isolating switch and the fire pump con troller isolating switch must be opened Separate ATS for Auxiliaries A separate ATS must s
201. s 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 equipment or oth er possible source of ignition near the fuel system Generator Set Starts When Not Scheduled 1 Y lt 1 Two wire starting only The operation selec tor switch on the generator set control panel should be in the Remote position Power Generation 5 15 tor switch on the generator set control panel should be in the Remote position AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death For this reason do not touch or allow clothing tools or jew elry to contact exposed electrical terminals whenever the cabinet door is open Make sure you are standing on a dry insulating surface Three wire starting only The Auto Stop Handcrank switch on the 3 Wire Start module should be in the Auto position Check the change over clock to verify the change over schedule The procedure for checking the change over program is de scribed under Programming the Change over Clock If a change over is incorrectly programmed re fer to the change over clock programming pro cedure Redistr
202. s strictly prohibited GA Power 5 7 Generation 2 ofi Y lt Two Wire Starting The starting circuit is a basic supervisory function of the electronic 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 signals the generator set to start An open switch signals the electric generator set to stop The two wire start circuit uses terminals B GND ground and RMT of terminal block TB2 Figure 5 5 There are two B and two RMT terminals on TB2 The upper B and RMT terminals are con nected to like terminals on unit 2 The lower B and RMT terminals are connected to like terminals on unit 1 The TB2 GND terminal is connected to the GND terminals on both units In some applications the jumpers between terminals 2 and upper B and between 7 and lower B are removed Refer to the generator set control schematic and to the in terconnection wiring diagram Three Wire Starting Option The optional three wire starting control available on 40 to 125 ampere switches only enables the transfer switch to start and stop a three wire start generator set Three wire starting logic is similar to a single pole double throw switch A common is closed to one side to send a start signal and to the opposite side to send a stop signal In addition to start and stop functions the control has an over crank relay a preheat relay tw
203. sides of the transfer switch The interlock assembly must hold one side open so that only one side closes at at time 13 Replace the linear actuator as described in the Linear Actuator Removal and Replacement section for 300 to 600 ampere switches Fol low steps 2 through 9 in the Replacing Actuator section 14 Test the switch for proper operation and close the cabinet AUXILIARY SWITCH REMOVAL AND REPLACEMENT 300 TO 600 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the auxiliary switch assembly for 300 to 600 ampere switches Redistribution or publication of this document by any means is strictly prohibited AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing Removing Auxiliary
204. sonal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the auxiliary switch assembly for 800 and 1000 ampere switches Removing Auxiliary Switch Assembly 1 Open the transfer switch cabinet door 2 Remove the hex head capscrew flat washer and lock washer that secure one of the rod end assemblies to the end of the actuator rod 3 Remove the rod end assembly Figure 4 16 and slide the actuator rod out of the actuator motor 4 Loosen and remove the twelve machine screws with flat washers that secure the three plastic switch covers to the switch base and lift off the switch covers Figure 4 16 5 Remove the hex head machine screws that se cure the terminal bracket to the base Move the bracket to the side to allow access to the auxil iary switch terminals 6 Remove the control wiring leads from the auxil iary switch terminals Figure 4 20 7 Close the transfer switch to the side you are working on and remove the hex head machine screws that secure the auxiliary switch assem bly brackets to the base Lift out the auxiliary switch assembly 8 Remove the round head machine screws Flat washers and nuts that secure the auxiliary switches to the bracket Figure 4 20 and lift Power Generation out the auxiliary switches and insulating barri ers Replacing Auxiliary Switch Assembly 1 In
205. spond directly to signals from the Power Sentry Power Generation 6 6 6 Timing run Seconds 60 Transition SC1583 FIGURE 6 4 PROGRAM TRANSITION MODULE No u Signal Module 16 Timing SC1584 Delay Seconds FIGURE 6 5 SIGNAL MODULE Redistribution or publication of this document by any means is strictly prohibited The Source 1 and Source 2 Available relays are en TABLE 6 1 AUXILIARY RELAY OPTIONS ergized when their respective power sources are producing adequate power 24 VAC Coil Installed Not Wired m 24 Coil Emergency Connected Relay In utility to utility applications the Backup Source 24 VAC Coil Normal Connected Relay Available relay is energized whenever the desig 24 VAC Coil Emergency Source Available Relay nated backup source is producing adequate power 24 VAC Coil Normal Source Available Relay All relay contact connections are made at TB3 Re fer to sheet 1 of your schematic and wiring diagram package To set the time delay align the slot on the poten tiometer with the desired marking on the faceplate Figure 6 5 If a time delay is desired make sure that the Delay No Delay switch is in the Delay position Auxiliary Relays Option Optional auxiliary relays provide contacts for ener gizing external alarms remote indicators and con trol equipment such as louver motors and water pumps Connecti
206. stall the control wiring leads on the corre sponding switch terminals Leads are marked with the terminal numbers S2 NO S5 NC S7 C etc for identification Refer to Figures 4 8 4 9 and 4 10 for identification of auxiliary switch terminals Place the terminal bracket in position on the base and secure it with the hex head machine screws Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem torque Place the plastic switch cover in position and secure with machine screws flat washers and self locking nuts Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emergen cy power source Place the operation selec tor switch in the Remote position Test the switch for proper operation and close the cabinet TORQUE TO 10 TO 15 IN LBS 1 1 TO 1 7 Nem SC1561 BARRIERS FIGURE 4 10 AUXILIARY SWITCH 150 TO 260 AMPERES wer 4 1 6 Redistribution or publication of this document e Generation by any means is strictly prohibited Y lt LINEAR ACTUATOR REMOVAL AND REPLACEMENT 300 to 600 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emer
207. stall the insulating barriers and auxiliary switches in the brackets and secure with hex head capscrews 2 and nuts 2 Note that each switch must be assembled so the side with two terminals faces inward Figure 4 20 when the auxiliary switch assembly is installed 2 Install the auxiliary switch assembly on the base and secure the bracket to the base using the hex head machine screws Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem torque 3 Install the control wiring leads on the switch ter minals The leads are marked with the terminal numbers S2 NO S5 NC S7 C etc for identi fication Refer to figures 4 18 4 19 and 4 20 for identification of the auxiliary switch termi nals 4 Place the terminal bracket in position on the base and secure it with the hex head machine screws 4 Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque 5 Place the plastic covers in position and secure them with machine screws and flat washers Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque 6 Insert the actuator rod into the replacement ac tuator motor Hold the actuator ground brush up slightly to allow passage of the actuator rod 7 Secure the rod end assembly to the actuator rod with the hex head capscrew flat washer and lock washer Tighten the capscrew to 70 to 75 in lbs 7 9 to 8 5 Nem torque Fit the rod as sembly into the handle of the closed switch as sembly 8 If a generator set is the Emergency power source conne
208. t 103194 SI2UINO2 AMHITIXDU HILIAS 3SN YaWOLSND 3043 HILTAS Aud TIIXNY TIUHNON MODIFIED 626 1762 SHEET 1 OF 5 t d e atic this documen is strictly prohibite ion of tribution or public t by any means o neration eT 25 G gt lt atc oz Za 22 42 22 lt 5 in lt II or Ow ug WW 2 IO Ne cc LL cc OESS r E lt 2 a 20utf o LL fc u a og Fu 2 lt tc tc gt lt o tc a Lu tc lt m lt o 5 lt a 2 z lt I o AON39U3W3 01 23 1 911 NOILISOd 250 1H9I 378VTIVAV 39gn0S AON39U3W3 er ksi x gt lt 537679 z CVO7 1 610 29 x 712 HOLIMS LOSNNOOSIO SOLOW HV3NI1 uaxv3ua8 1 HOlIOVgVO HOLOW I1H9I 318V1TIVAV 32 08 TVHHON MOOT 3SIOU3X3 190 WWYON OL tu34SNVHI 1H9I1 NOILISOd VWBON HOLIMS ti33SNVt138 1VNti0N 1531 SNOTLOSNNOD HOS E 133HS 33S NW WWHON OL 0358010 HOLIMS YJJSNYYL HLIM ONY O3219H3N3 30 NMOHS SJJIA30 TM H1HY3 S1104 00E 6 20 6 er SLINN NO 0361 SI EL S3
209. t of the manual operator handles and presents a hazard of severe personal injury Keep hands clear of the handles when switching back to automatic operation 5 Move the Motor Disconnect switch to the Auto position 6 Close and lock the cabinet door Overcrank Reset 3 Wire Start Only An overcrank condition exists when the generator set fails to start within the overcrank time limit When this condition occurs the Lockout lamp on the 3 Wire Start module will light To restore the au tomatic starting circuit 1 Correct the engine starting problem 2 Push the Overcrank Reset button inward and release to reset the overcrank relay Redistribution or publication of this document by any means is strictly prohibited TROUBLESHOOTING The following procedures describe preliminary troubleshooting checks Priority Generator Set Fails But Backup Generator Set Does Not Start 1 Two wire starting only Check the generator set The operation selector switch on the gen erator set control panel should be in the Re mote position Check for fault indicators on the generator set control AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death For this reason do not touch or allow clothing tools or jew elry to contact exposed electrical terminals whenever the cabinet door is open Make sure you are standing on a dry insulating surface
210. t secure the plastic switch cover to the switch base and lift off the cover 3 Loosen the two machine screws that secure the terminal bracket to the base Move the ter minal bracket to allow access to the auxiliary switches 4 Remove the control wiring leads from the auxil iary switch terminals Figure 4 5 5 Remove the hex head machine screws that se cure the auxiliary switch assembly bracket to the base 6 Disengage the auxiliary switch lever from the transfer switch crossbar and lift out the auxilia ry switch assembly Use care when disengaging the switch lever from the crossbar to avoid cracking the switch lever 7 Remove the hex head machine screws and nuts that secure the auxiliary switches to the bracket Figure 4 5 and lift out the four auxilia ry switches insulating barriers and switch le ver Power Generation 10 Replacing Auxiliary Switch Assembly 1 Place the auxiliary switch lever in the bracket as shown in Figure 4 5 Note that the end of the lever with the octagonal hole must engage the transfer switch cross bar when the auxiliary switch assembly is installed Install the auxiliary switches 4 and insulating barriers 5 in the bracket and secure with hex head machine screws 2 and nuts 2 Tighten to 10 to 15 in Ibs 1 1 to 1 7 Nem torque Note that each switch must be assembled so the side with two terminals Figure 4 5 is facing in ward toward the other auxiliary s
211. t to generator set transfer switch which in turn provides power to the generator set source lugs on a utility to generator set transfer switch The function of the standby set start sequencer is to respond to a remote start signal from the utility to generator set transfer switch by directing a start sig nal from the generator set to generator set transfer switch to the RMT start input of the generator set that is selected as the preferred source The stand by set start sequencer permits normal backup set operation if the preferred active set fails The se quencer also permits normal changeover clock ini tiated operation Refer to the system interconnection drawings if ap plicable Power Generation 5 13 Horn Stlenced 300 3998 FIGURE 5 13 ALARM MODULE CUSTOMER CONNECTION c A T e m z e O 300 3893s FIGURE 5 14 STANDBY SET START SEQUENCER OPTION Redistribution or publication of this document by any means is strictly prohibited OPERATION Automatic Operation The automatic transfer switch is set for automatic operation by placing control switches in the posi tions given below The generator set must also be set for automatic operation Motor Disconnect Switch on the Accessory Control Panel Auto position Source selector switch on the cabinet door Auto position Stop Auto Handcrank switch three wire start Auto position Operation selector switch
212. ted Programmed Transition The optional Program Transition module Figure 2 5 is used to introduce a pause during transition Programmed transition allows the transfer switch to assume a midtransition position for an adjustable interval of time In this position the load is not con nected to either Normal or Emergency power source This feature allows residual voltage from inductive loads to decay to an acceptable level be fore transfer is completed The length of time that the transfer switch is in the midposition can be adjusted from 0 to 7 5 seconds or 0 to 60 seconds depending on the timer option The proper adjustment is a function of the load decay time A Delay No Delay switch permits bypassing the tim er delay if it is not needed or if the timer has failed The timing circuit is triggered by the same signal that is used to drive K1 or K2 The output of the tim ing circuit is used to energize K3 Contacts K3 6 K3 9 and contacts K3 4 K3 7 acting in con junction with auxiliary switches S9 and S5 respec tively control the linear actuator circuit When the normally open contacts of K3 close the linear ac tuator circuit is completed and the switch contacts are moved from the neutral position to their original destination Refer to sheets 2 and 5 of your schematic and wir ing diagram package Power ot Y Generation 2 10 Timing e run Seconds 60 Program e Transition SC158
213. th the four screws Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem 10 ACTUATOR ACTUATOR ROD MOTOR GROUND BRUSH WHITE dE FIGURE 4 12 LINEAR ACTUATOR 300 TO 600 AMPERES SC1474s Xsc 1417 Power Generation 4 19 Redistribution or publication of this document by any means is strictly prohibited EF ESF BLOCK AND CROSS BAR ASSEMBLY REMOVAL AND REPLACEMENT 300 to 600 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pres ents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and re placement of the block and cross bar assemblies for the 300 to 600 ampere switches Removing the Block and Cross bar Assembly Normal or Emergency 1 Remove the linear actuator as described in the Linear Actuator Removal and Replacement section for 300 to 600 ampere switches Remove the hex head capscrews lock wash ers and flat washers that secure the interlock bar to the int
214. the following ranges Function Adjustment Range Dropout 105 to 135 of nominal voltage Delay 0 to 120 seconds To set the dropout percentage and time delay align the slots on the potentiometers with the desired markings on the Power Sentry cover Figure 2 14 Redistribution or publication of this document by any means is strictly prohibited ofi Y lt Frequency Sensor Adjustments The optional frequency sensor monitors the source frequency When the source frequency is outside the acceptable band dropout occurs The band is centered about the nominal system frequency 50 or 60 hertz The dropout bandwidth is 2 5 wider on each end than the pickup bandwidth The pick up bandwidth is adjustable An adjustable dropout time delay allows the control to ignore momentary dips or rises in frequency Frequency sensor pickup bandwidth and time delay are adjustable over the following ranges Function Adjustment Range Bandwidth 5 to 20 of nominal Delay 0 to 15 seconds To set the pickup bandwidth and time delay align the slots on the potentiometers with the desired markings on the Power Sentry cover Figure 2 14 Time Delay Module Adjustments The time delay module controls the following func tions Start time delay Stop time delay Transfer time delay Retransfer time delay The time delays on the standard time delay module are adjustable over the following ranges Delay Adjustment Range Start 0 to 1
215. the poten tiometer with the desired marking on the Power Sentry cover Retransfer Time Delay This delay begins when the preferred source voltage and frequency return After the delay the transfer switch can retransfer the load to the preferred source The delay allows the preferred source to stabilize before retransfer It has an adjustable range of 0 to 30 minutes To set this time delay align the slot on the poten tiometer with the desired marking on the Power Sentry cover Undervoltage Sensing Two voltage sensors one for the source 1 side and one for the source 2 side monitor source voltages for an undervoltage condition and generate signals which are sent to the time delay module If for ex Power Generation 5 5 ample an undervoltage condition is sensed on the priority source the voltage sensor module sends a signal to the time delay module that initiates and controls the timing for generator set start and the transfer of load The standard transfer switch has undervoltage sensing for all phases of the source 1 and source 2 power sources Undervoltage adjustment and calibration proce dures are described in section 2 Overvoltage and Frequency Sensing Option Overvoltage and frequency sensing are available as a single option Overvoltage Sensing With optional overvoltage sensing the sources are monitored for an overvol tage condition As with the standard undervoltage sensing the volt age sensors
216. ther board provides power to the time delay module during this timing period Because the generator set start signal is initiated by de energizing a relay a complete discharge of C1 produces a start signal After the start time delay has timed out a signal from the time delay module de energizes the nor mally energized two wire start relay K 11 lights the Start Gen Set lamp dimly and if applicable sends a start signal to the 3 Wire Start module On two wire start systems K11 contacts close and signal the generator set to run On three wire start systems a relay in the 3 Wire Start module signals the generator set to run The Start Gen Set lamp re mains lit as long as the control is signaling the gen erator set to run Redistribution or publication of this document by any means is strictly prohibited Source 2 Voltage Sensor The Source 2 voltage sensor monitors the voltage output from the gener ator set When the voltage rises above the pickup setting the sensor signals that the Emergency pow er source is available The Source 2 Available lamp lights and stays on as long as the Emergency power source is within the voltage and frequency settings of the voltage sensor Transfer Time Delay The transfer time delay be gins timing as soon as the voltage sensor signals that source 2 voltage is available The transfer time delay is adjustable from 0 to 120 seconds The Transfer Timing lamp lights to indicate that the tr
217. thin the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death Close the cabinet door 3 Move the Test Normal Retransfer switch to Test The generator set should start and as sume the load after the transfer time delay 4 At the end of the test period move the Test Normal Retransfer switch to the Normal posi tion if you want to retransfer load back to the Normal power source after the retransfer time delay To bypass the retransfer time delay and cause immediate load retransfer move the Test Normal Retransfer switch to Retransfer and release the switch will return to Normal The generator will stop after the stop time delay 5 In anticipation of scheduled or automatic gen erator set exercise check that the With With out Load selector switches are in the desired positions Refer to Generator Set Exercise 6 Close and lock the cabinet door Overcrank Reset An overcrank condition exists when the generator set fails to start within the time limit When this con dition occurs the Lockout lamp on the 3 Wire Start module will light To restore the automatic starting circuit 1 Correct the engine starting problem 2 Push the Overcrank Reset button and release Redistribution or publication of this document by any means is strictly prohibited PREVENTIVE MAINTENANCE Performing the yearly preventive maintenance procedures in Table 1 1 will result in o
218. ties to hold actuator lead wires in place Check the operation of the transfer switch and alignment of the actuator rod by manually opening and closing both the Normal and Emergency switch assemblies Place the plastic switch cover in position and secure with machine screws 4 and flat wash ers 4 Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emergen cy power source Place the operation selec tor switch in the Auto or Remote position Test the switch for proper operation and close the cabinet GROUND ROD END ASSEMBLY HEX HEAD CAPSCREW WITH LOCK WASHER SC1555s FIGURE 4 2 LINEAR ACTUATOR 40 TO 125 AMPERES Power Generation 4 3 Redistribution or publication of this document by any means is strictly prohibited BLOCK AND CROSS BAR ASSEMBLY REMOVAL AND REPLACEMENT 40 to 125 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control pan el Disconnect both the Normal and Emergency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first
219. tion of this document Generation by any means is strictly prohibited Replacing Block and Cross Bar Assembly 1 Install the lug terminals on the block and cross bar assembly and secure with hex head caps crews ring terminals and spring washers Tighten to 10 to 12 ft Ibs 13 6 to 16 3 Nem torque 2 Install the interlock arm and secure with the two round head capscrews Tighten the screws to 15 to 20 in Ibs 1 7 to 2 3 Nem torque 3 Install the two threaded hex spacers in the back of the block and cross bar assembly 4 On 4 pole switches Figure 4 9 Secure the neutral block with the machine screw that was removed from the center hole Tighten to 70 to 75 in lbs 7 9 to 8 5 Nem torque Fill the cavity in the block with adhesive silicone to complete ly cover the screw head Pivot the neutral block to permit placement of the block and cross bar assembly 5 Secure the block and cross bar assembly to the base with the hex head capscrews Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem torque 6 On 4 pole switches Figure 4 9 A Pivot the neutral block back to its correct position B Secure the neutral block with the two Phil lips screws and the spacer Tighten to 70 to 75 in lbs 7 9 to 8 5 Nem torque C Secure the neutral jumper bus bar with the hex head capscrew terminal ring spring washer and load lug Tighten to 10 to 12 ft lbs 13 6 to 16 3 Nem torque D Position the neutral block arc chute and cov
220. tion or publication of this document by any means is strictly prohibited 7 Nonautomatic Remote INTRODUCTION This section provides information for a transfer switch with a nonautomatic remote control NORMAL Some ol the information on theory of operation and troubleshooting in sections 1 2 and 3 is applicable Refer to this section 7 for an overview of the non automatic remote transfer switch Refer to the five sheet schematic and wiring diagram package that was shipped with the transfer switch for specific in formation about its configuration Section 4 of this manual covers transfer switch as sembly service procedures for all configurations I i I I L Transfer Switch Application Transfer switches are an essential part of a build ing s standby or emergency power system The Normal power source commonly the utility line is STANDBY backed up by a Standby power source often an Se electric generating set A transfer switch supplies FIGURE 7 1 LOAD TRANSFER SWITCH the electrical load with power from one of these two TYPICAL FUNCTION power sources The load is connected to the com mon of the transfer switch Figure 7 1 Under normal conditions the load is supplied with power from the Normal source as illustrated If the Normal power source must be interrupted the load is transferred to the Standby power source When Normal power returns the load should be retrans ferre
221. to avoid touching electrical contacts whenever the cabinet door is open 1 Place the Test With Without Load selector switch on the Power Sentry control in the Without Load position The Test With Without Load selector switch must be in the Without Load position 2 Close the cabinet door AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death Close the cabinet door 3 Move the Test Normal Retransfer switch to Test The generator set should start and run 4 At the end of the test period move the Test Normal Retransfer switch to the Normal posi tion The generator will stop 5 In anticipation of scheduled or automatic gen erator set exercise check that the With With Power Generation 1 8 out Load selector switches are in the desired positions Refer to Generator Set Exercise 6 Close and lock the cabinet door With Load Standby System Test 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 1 Place the Test With Without Load selector switch on the Power Sentry control in the With Load position The Test With Without Load selector switch must be in the With Load position in order to test with load 2 Close the cabinet door AC power wi
222. ugh 0 1 or 0 47 farads to provide power to the time delay module from the time Normal power is lost until Emergency power is available Refer to Control System Operation Additional inputs to the utility to generator set mother board include e Test exercise inputs e Manual retransfer input e Transfer inhibit input e Instant retransfer input e Delayed transfer and retransfer inputs The test exercise inputs from the Test Normal Re transfer switch and from the optional exerciser clock are used to start the generator set Their function is described under Control System Opera tion in this section Closure of a set of contacts across the remote test transfer inputs terminals 7 and 8 of TB2 causes the transfer switch to sense a simulated utility power failure and send a start run signal to the gen erator set The load is transferred to the generator set when generator set power becomes available On 300 3090 mother boards the With Without Load switch must be in the With Load position On 300 3953 mother boards this input is NOT depen dent upon the position of With Without Load switch The manual retransfer input from the optional Auto Manual switch blocks automatic retransfer and permits only manually initiated retransfer Power Generation 2 3 The Transfer Inhibit input when open prevents Emergency power from being sensed This input is at terminals 5 and 6 of TB2 The Instant Retransfer input from th
223. umper bus bar load bus bar load lug support block as sembly Power Generation 7 Remove the control wiring leads from the pow er source terminals 8 On 4 pole switches Figure 4 9 Before the block and cross bar assembly can be re moved the neutral block assembly must be loosened and pivoted slightly out of the way A Remove the two machine screws that se cure the arc chute cover Remove the cov er and the arc chute B Remove the hex head capscrew terminal ring spring washer and load lug that se cure the neutral jumper bus bar Remove the neutral jumper bus bar C Remove the two Phillips screws and the spacer that secure the source lug side of the neutral block D Pivot the neutral block slightly away from the block and cross bar assembly Use care when removing the block and cross bar assembly from the base Careful ly disengage the cross bar from the auxiliary switch assembly to avoid cracking the switches 9 Remove the remaining hex head capscrews that secure the block and cross bar assembly to the base and carefully remove the assem bly 10 Remove the two threaded hex spacers from the back of each block assembly and save for reuse 11 On 4 pole switches Figure 4 9 With a screwdriver dig the glue out of the cavity in the base of the neutral block Remove the ma chine screw that secures the neutral block and remove the neutral block 12 Remove the two round head machine s
224. upply all pump room auxilia ries 40 40 40 70 70 125 125 125 25 25 00 0 0 5 5 9 899 00 Redistribution or oua ge Q9 document by any means is strictly prohibited NORMAL FIRE PUMP ALTERNATE SOURCE FEEDER SOURCE p 0 NOTE A GENERATOR ISOLATING FIRE PUMP SWITCH SERVICE DISCONNECT NORMAL GENERATOR a SOURCE UPSTREAM FEEDER OVERCURRENT DEVICE BREAKER O fuse or circuit breaker v TRANSFER TO OTHER SWITCH LOADS PUMP ROOM rs FIRE PUMP CONTROLLER A Outside building or fire rated runs Ref NFPA 20 1993 6_3 1 1 B The fire pump feeder breaker is sized according to the NEC per Article 430 C These feeder breakers can be mounted FIRE PUMP MOTOR on the generator set FIGURE 1 TYPICAL FIRE PUMP CONTROLLER AND TRANSFER SWITCH ARRANGEMENT Lan Pm 7 2d Powe J Redistribution or pub Page 3 Of Siocument rh Generation by any means is strictly prohibited k I Phase Sequence Monitor The phase sequence monitor Figure 2 is con nected to and senses A B and C phases of util ity power If there is a phase reversal or a loss of one phase a normally energized relay drops out clos ing a set of contacts These relay contacts are wired to the remote test input terminals 7 and 8 of TB2 When the contacts across terminals 7 and 8 of TB2 close the generator set start transfer of load se qu
225. ures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components Improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety precautions in your generator set manuals Automatic transfer switch operation results in rapid movement of the switch mechanism and presents a hazard of severe personal injury Keep hands clear of the switch handles when switch ing to automatic operation TROUBLESHOOTING 3 1 Transfer Switch Does Not Retransfer When Normal Voltage Returns After A Power Outage This procedure is to be performed with the generator set running and Normal voltage on line MAKE SURE THAT THE MOTOR DISCONNECT SWITCH IS IN THE AUTO POSITION NOTE if the Program Transition module is used and transfer switch only moves to the mid transition disconnected position the trouble may be in Program Transi tion module or relay K3 Place the Delay No Delay switch in the No Delay position If retransfer occurs replace the Program Transition module If retransfer does not occur replace K3 When taking voltage measurements be sure that the probe penetrates the confor mal coating on the boards 1 Is the Retransfer Timing lamp on the time delay board lit 15 t
226. voltage is present on all phases of the source being calibrated Normal or Emergency On voltage sensors with the frequency sensing option the source frequen cy must be within the limits set by the Frequen cy Bandwidth potentiometer 2 Turn the Undervoltage Pickup and Dropout po tentiometers on the voltage sensor fully clock wise 3 Turn the Undervoltage calibration Cal poten tiometer fully clockwise The Source Available lamp that corresponds to the source sensor be ing calibrated should be on If the Source Avail able lamp fails to come on and the voltage sen sor has an overvoltage sensing option turn the overvoltage Dropout and Cal potentiometers fully clockwise 4 Turn the Undervoltage Cal potentiometer counterclockwise until the Source Available lamp turns off 5 Slowly turn the Undervoltage Cal potentiome ter clockwise until the Source Available lamp just turns on again 6 The undervoltage sensor is now calibrated If the overvoltage sensor was adjusted in Step 3 then recalibrate it by using the overvoltage sensor calibration procedure Undervoltage Pickup and Dropout Adjustments Undervoltage dropout occurs when an undervol tage condition is sensed Pickup occurs when an acceptable voltage is sensed Undervoltage drop out and pickup are adjustable over the following ranges Function Adjustment Range Pickup 85 to 10096 of nominal voltage Dropout 75 to 98 of pickup voltage Power Gener
227. wer Sentry includes voltage sensing circuits time delay circuits and control relays There are also several adjustment potentiometers and indicator lamps on the Power Sentry The ad justments must be performed only by qualified ser vice personnel Accidental actuation of the linear motor can cause severe personal injury Dis able the motor as described below before mak ing any adjustments Place the Motor Disconnect switch Figure 6 3 in the Off position when making adjustments Return the switch to the Auto position after ad justments are completed Redistribution or publication of this document by any means is strictly prohibited OPTIONAL OPTIONAL SIGNAL PROGRAMMED MODULE TRANSITION INDICATOR LAMPS OPTIONAL METERS SWITCHES ACCESSORY CONTROL PANEL DISCONNECT SWITCH FIGURE 6 3 UTILITY TO UTILITY CABINET INTERIOR Power Generation POWER SENTRY CONTROL AUTOMATIC TRANSFER SWITCH SC1581 2s Redistribution or publication of this document by any means is strictly prohibited 2 gt Power Sentry Time Delays Transfer Time Delay This delay prevents nui sance transfers to the backup power source caused by brief line fluctuations After the delay the transfer switch transfers the load to the backup power source It has an adjustable range of 0 to 120 seconds To set this time delay align the slot on the poten tiometer with the desired marking on the Power Sentry c
228. witch assem bly Manually close the contacts that will be coupled to the auxiliary switch lever Hold the auxiliary switch assembly in position on the base and check the alignment of the auxiliary switch lever When the transfer switch assembly is closed the auxiliary switch must be aligned as shown in Figure 4 5 Move the auxiliary lever as required to get the correct alignment Secure the bracket to the base using the hex head machine screws and tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque Install control wiring leads on the correspond ing switch terminals Leads are marked with the terminal numbers S2 NO S7 NC S9 C etc for identification Refer to Figure 4 5 for identifi cation of the auxiliary switch terminals Place the terminal bracket in position on the base and secure it with the hex head machine screws Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem Place the plastic switch cover in position and secure with machine screws 4 and flat wash ers 4 Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem torque If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emergen cy power source Place the operation selec tor switch in the Remote position Test the switch for proper operation and close the cabinet Redistribution or
229. ws and spring wash ers Make sure the mating surfaces have a coating of electrical joint compound Tighten the capscrews 10 to 12 ft lbs 13 6 to 16 3 Nem Secure the load bus bars to the jumper bus bars with the capscrews lock washers flat washers spring washers ring terminals and nuts Figure 4 13 and 4 14 Be sure to apply a thin coat of electrical joint compound between the current carrying surfaces Tighten 70 to 75 in lbs 7 9 to 8 5 Nem Install the actuator handle on the block assem bly with the shoulder screws and lock washers Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem Ap ply a thin coat of lubricant Onan part number 524 0157 to the slot in the handle Connect the power source supply wires to the lug terminals Tighten the lug terminals to the torque value silkscreened on the transfer switch cover Connect the control wiring leads to the power source terminals Control wires are marked NORM A B C or EMER for identification Power Generation 10 Connect the control wiring leads to the jumper bus bars Control wires are marked LOAD A B C for identification 11 Apply thread sealant blue Loctite 242 Onan part number 518 0309 is recommended to the threads of the interlock bar capscrews Install the interlock bar and secure to each interlock arm with a hex head capscrew lock washer and flat washer Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem 12 Attempt to close both

OT III 962

Contents

Download Pdf Manuals

Related Search

Related Contents