Hubbell LX-440 User's Manual
Contents
1. All other standard customer connections are made to PTB1 on the left side of the mounting panel Use approved 14 gauge wire for all control connections Typical field connections are shown below PTB1 1 and 2 Engine Start Contact for generator set TSN Auxiliary Contact Normal source TSE Auxiliary Contact Emergency source After installation is complete perform a transfer test as described in section 6 0 Maintenance 4 0 Operation Refer to the schematic and wiring diagrams that are provided with the transfer switch These drawings are provided in a packet along with this manual A schematic is also posted on the inside of the cabinet door Page 5 of 16 Pages Transfer Switch The Hubbell Transfer Control Module LX 301 controls transfer to the emergency source and retransfer to the normal source The LX 440 non automatic transfer switch does not come with a Control Module A selector switch initiates transfer and retransfer Automatic Operation Transfer to Emergency Source The Control Module monitors the normal source phase voltage for acceptable limits of drop out and pick up A NORMAL OVERRIDE ON MOMENTARY OUTAGE time delay is provided to override voltage dips causing nuisance starting of the engine generator set If the normal source voltage is restored above the pick up setting within the time delay period the delay timer is reset If the NORMAL OVERRIDE ON MOMENTARY OUTAGE time delay expires before the normal sou2. CAUTION Do not leave the handle on the square bar The handle prevents closure of the cabinet door and may cause damage to or prevent emergency operation of the transfer switch Page 10 of 16 Pages Transfer Switch Auto Test The following procedure is an example for testing the automatic transfer switch A procedure should be written by qualified personnel that is applicable to the facility the transfer switch options and the power distribution system Refer to job specifications for timing delays CAUTION Always close enclosure door when switch transfers with power connected 1 Press the TEST push button until the engine generator starts or automatic transfer switch transfers if emergency source is a second utility 2 Verify that the NORMAL indicator goes off and the EMERGENCY indicator comes on per the time delay settings 3 Verify that the automatic transfer switch transfers to the emergency source 4 Verify that the automatic transfer switch retransfers to the normal position after 30 minutes or press the optional BYPASS RETRANSFER TO NORMAL push button 5 Ifthe emergency source is a generator set verify that the engine runs unloaded for five minutes Troubleshooting SS O Hazardous voltage will shock burn A DANGER or cause death Do not touch until ALL power is disconnected WARNING Disconnect ALL power supply sources to the transfer switch before servicing to prevent shock or accident hazar
3. Hubbell Industrial Controls Inc A subsidiary of Hubbell Incorporated HUBBELL 4301 Cheyenne Drive A ZZ Archdale NC Telephone 336 434 2800 FAX 336 434 2803 Instruction Manual Transfer switches LX 440 Non Automatic LX 450 Automatic 100 200 260 400 600 800 1000 1250 Ampere 2 3 4 Pole Publication No 201 April 2001 Transfer Switch Table of Contents 1 0 TRO AUC HUG Use vss sevesescictas ee testcetcnaecen shen ss Sane vauteccotobecasiedsabeuss saebevaeesbssudeeesuavencanscusustasevesinsavosceaseuoeetaxe 3 2 0 Specifications and Certifications sesssesssessssesssocssoossoosssssssocsssocssoossoossssesssesssocsssoossoossosssssssssese 4 Specials tdo a ao leu ae tad 4 Cerni AUTOS ee nna ad a ale A E A 4 3 0 Instala ti a di da inca 4 as e E ES E 5 MCAT LOIN cst cada iawn av Pee tales Cada bbe A A Aa a a a ab 5 Line COME CHO a T E eae dase neg T 5 40 Operations A cossavsebuendecuapseuoudd aa eoet 5 Automatic Op rations nona o n Merete ec a o e te alone 6 5 0 Standard and Optional Features c ccccccsscsscsscssssscssscccssscccsscscsssssccsescssscscssscssesccssesocsscseesees 7 Standard ESE o 7 Optional Feat reS A A E des Saudi a E ge EEE 8 COMA spsccessecscsnasectsdacesnccucscsuteoasusincansisncdeucdeasecescsctusasssseaseessaeCntedeudaanscsdeuineteunedbeasiaeuscsssunnesens 10 Transfer VCS bata tan Es bandiay ceded lacatehnad a e a enum A a aman 10 TROUT ES OUI soars cash esc A A teva cet E
4. R7 This option provides terminal points for the connection of remote devices that are normally closed and wired in series with the TEST push button An open circuit simulates failure of the normal source and initiates transfer to the emergency source Selector Switch R2 R4 Selector switches are available to set the transfer switch for testing automatic or manual mode and to test start the engine for troubleshooting and maintenance Selector switches with an OFF position option R2 include an OFF indicating light PL4 white Switches with a TEST position initiate a load transfer NEUTRAL POSITION TIME DELAY N When the normal source contacts open the NEUTRAL POSITION TIME DELAY starts The timer circuit on the TCR board temporarily disconnects the power source to the switching mechanism while the automatic transfer switch is in the neutral position normal and emergency source contacts open The adjustable timer is usually set for three seconds The red START DELAY LED indicates the timer is counting After the delay the green END DELAY indicates the TR timer relay is energized to reconnect power to the switching mechanism Page 9 of 16 Pages Transfer Switch 6 0 Maintenance DANGER Do not touch the transfer switch until ALL power is disconnected Shocks burns or death may result from high voltage CAUTION Only personnel who are familiar with the power distribution system and this manual should be allowed to insp
5. Controller with automatic transfer switch to meet NFPA 20 specifications Pressing this button allows the transfer switch to retransfer to the normal position bypassing the RETRANSFER TO NORMAL SOURCE time delay Phase Rotation Monitor H1 The PRM Phase Rotation Monitor contacts open if the phase rotation of the normal power source is not correct If the proper phase sequence is not sensed the LX 301 Control Module does not output a signal to the TCR board to retransfer the transfer switch to the normal source Auxiliary Contacts A1 A4 One additional NO NC set of contacts may be added to the normal and the emergency source side of the transfer switch The contacts are rated for pilot duty 10 A at 125 or 250 VAC BYPASS TRANSFER TO EMERGENCY push button S2 This push button overrides the time delay to transfer to the emergency source Page 8 of 16 Pages Transfer Switch Plant Exerciser B1 B2 The Plant Exerciser option is a seven day clock that provides for automatic test operation of the generator set at pre selected intervals The clock is powered by a fused circuit from control transformer XFMR3 The Plant Exerciser option is used in conjunction with contacts to initiate engine starting without a load transfer option B1 Option B2 includes a selector switch to simulate a power failure with or without a load transfer Refer to section 8 pages 14 15 for instructions to program the Plant Exerciser timer Remote Test
6. O 11 SENE Si e acu sl o a celta tee Seats do a e ES 11 7 0 Transfer Control Relay Board c lt cc csscscesscoscssses sosenscsicsechocsvsssebucvenchscctonscoucsdecasdsevavessvavecensaceetes 12 8 0 Plant Exerciser MiMi Gk de ei 14 A A A aie a E 14 Programming A A ta real 14 9 0 Spare Parts and Drawing References ssesssecssooesoosssossssessssesssocssoossoosssosssoeessocssoossoossosssssesssese 16 A A a e cats 16 Drain References scat Neate tee ck hatte le Seen E sl cd aged Sad etre eshte ESAS 16 Page 2 of 16 Pages Transfer Switch 1 0 Introduction Hubbell s non automatic LX 440 and automatic LX 450 transfer switches are available in 2 3 and 4 pole models with ampere ratings of 100 to 1250 A The transfer switches are available as open type or in an individual cabinet The automatic transfer switch has a Solid State Transfer Control Module LX 301 that monitors voltage and controls the transfer to and from the normal and emergency sources The non automatic transfer switch has a selector switch to manually initiate transfer A handle is included with all transfer switches to manually close the normal or emergency contacts Emergency Source Normal Source Switching Mechanism a ees es ee A eo Normal Source Transformer Control Relay Board Module LX 301 Emergency Source Transformer I I I v To engine start contacts If generator backup Figure 1 1 Block Diagram of automatic tran
7. ars to end the override return to run mode To delete a program a Press Prog to display the program to delete b Press m until the display is blank c Press h until the display is blank d Press to return to run mode Page 15 of 16 Pages Transfer Switch 9 0 Spare Parts and Drawing References The following lists contain part numbers and drawing numbers for identification and for ordering If materials are needed from Hubbell contact the local Hubbell representative to request the desired information or parts Spare Parts Spares Spares Doseripton Partno SARS Transformer Phase Rotation Monitor 100 VA 57511355 208 260 V 57418 398 200 VA 57511343 440 480 V 57418 399 w o Timer w Switch 49271 101 402067520 EA w Timer w Switch 49271 102 w o Timer w Switch 49271 104 120 V Bulb 80324905 Black Push Button 80320400 NO AR relay 2 pole 31658 123 12 point terminal strip 57520323 ARI relay 3 pole 31658 112 LX 301 Control Modules Standard Standard 200 V 3 pole 60 Hz 90363 001 240 V 3 pole 60 Hz 90363 005 208 V 3 pole 60 Hz 90363 002 440 V 3 pole 60 Hz 90363 006 220 V 3 pole 60 Hz 90363 003 460 V 3 pole 60 Hz 90363 007 230 V 3 pole 60 Hz 90363 004 480 V 3 pole 60 Hz 90363 008 Engine Start Relay 12 VDC 31658 076 ne Drawing No No Title Drawing No No Title 49271 500 Schematic Transfer Control Relay Board Notes As built schematics and wiring diag
8. d Before troubleshooting perform the following checks a visual inspection for physical damage b ensure that all switches are in the normal operating position c ensure that the engine generator is operational or the alternate source is available d ensure that all wiring connections are secure See Table 6 1 page 12 for some examples of possible problems that could occur and steps to take for repair Settings Voltage and time delay settings are factory set per job specifications DO NOT CHANGE VOLTAGE SETTINGS WITHOUT CONSULTING HUBBELL ICD The table below lists the typical time delay settings Page 11 of 16 Pages Transfer Switch Time Delay function Typical factory setting Adjustment Range NORMAL OVER RIDE ON 1 second engine generator 0 5 to 6 seconds MONETARY OUTAGE 3 seconds utility RETRANSFER TO NORMAL 30 minutes 2 to 30 minutes ENGINE RUNNING UNLOADED 5 minutes 2 to 30 minutes EMERGENCY OVER RIDE ON 1 second 0 5 to 6 seconds MOMENTARY OUTAGE TRANSFER TO EMERGENCY 2 seconds 0 seconds to 5 minutes NEUTRAL POSITION TIME DELAY 3 seconds 1 second to 10 minutes optional Frequency Monitor 30 to 100 Hz Table 6 1 Troubleshooting conan Possible cause checks acion Switching mechanism ee ee ee Actuate transfer switch jammed P manually Automatic transfer ee i eck for output switch does not transfer Transformer fault onto p Replace transformer LED s on Control Module indicate proper Inspect board fo
9. ect or perform maintenance on the transfer switch Preventive maintenance The following checks should be preformed as part of routine maintenance A transfer test of the transfer switch should be preformed every week The transfer switch should be kept clean of dust and moisture DO NOT USE A BLOWER TO CLEAN the switch or the inside of the enclosure Always use a clean cloth or vacuum to prevent debris from lodging in the switching mechanism Check all wiring connections Visually inspect the contacts for surface deposits and pitting This inspection should be preformed annually Transfer Test After installation and each week thereafter check the operation of the transfer switch by performing a manual and an automatic transfer Manual Test WARNING Disconnect the emergency and normal power sources before transferring with the handle Manual operation is only for testing the mechanical operating mechanism or switching when there is a control problem Manual operation of the transfer switch is performed by sliding the square notch at the end of the handle onto the end of the square bar on the left side of the switch Push the handle up to transfer to the normal source A To transfer the switch to the emergency source B insert a screw driver in the TRIP hole to put the switch in the neutral position Then push the handle up and insert a screw driver into the SELECT hole to transfer the switch to the emergency source
10. imer to transfer the transfer switch with load or no load once a week and run generator set for thirty minutes Friday at 9 00 a m a Press the Prog program button to display the day of the week and time setting for the program b Press the Aa ON OFF button once to display the ON open circle symbol c Press h to set the hours until 09 AM is displayed d Press m to set the minutes until 00 is displayed e Press Day eight times to select 5 Friday as the day of the week to run Press the button four times to select Monday or up to 10 times to select Sunday f Press Prog button g Press ule twice to display the OFF open circle with dot symbol h Repeat steps c d and e to set 9 30 a m Friday i Press Prog button j Press the time run mode button To review the programming a Press Prog once to see the transfer time Page 14 of 16 Pages 3 4 Transfer Switch b Press Prog a second time to see the retransfer time c Press Prog a third time to see the number of additional program times Fr18 To manually override the Timer press the gt button a Pressing gt once transfers the Timer contacts output ON starts the engine Automatic control resumes after the next programmed event temporary override b Press twice consecutively turns the output ON permanent override c Press gt three times consecutively to turn the output OFF permanent override d Press gt until the symbol appe
11. lation section are applicable to the automatic transfer switch in the adjoining cabinet For automatic transfer switches sold as an individual unit and for additional information follow the procedures below Page 4 of 16 Pages Transfer Switch Receiving and Storage After receiving the transfer switch inspect the cabinet for any damage that may have occurred during shipping If the transfer switch is not installed immediately cover the cabinet and store in a dry area Condensation can corrode the contacts and other metal parts Location The transfer switch should be located as close as possible to the engine generator or to the alternate power source If possible there should be a clear line of sight between the transfer switch and the engine generator Line Connections Refer to the drawings posted inside the cabinet door and in the drawing packet for customer connections Before drilling and punching holes in the cabinet for wiring connections cover the transfer switch with a protective covering Small debris falling into the automatic transfer switch may jam the switching mechanism or may cause electrical failure Ensure that the normal primary emergency alternate and load isolation switches are open before making connections Connect the load normal source and emergency source power cables in the same phase sequence Refer to the latest NFPA 70 and Field Connections Wiring Diagram for cable sizes and torque requirements
12. lects one of four ranges Potentiometer P1 adjusts the time within that range The four ranges are 1 6 seconds 20 120 seconds 5 30 seconds 100 600 seconds 3 Manual Disconnect Switch not used on assembly 103 Opening this switch disconnects power from the control transformers to the switching mechanism Then the transfer switch can only be switched manually using the handle Assembly versions For LX 450 49271 101 No timer with MDS 49271 102 Includes timer and MDS 49271 104 No timer with MDS and monitor for AUTO MANUAL switch 49271 105 Includes timer MDS and monitor for AUTO MANUAL switch Page 13 of 16 Pages Transfer Switch 8 0 Plant Exerciser Timer Set the time 1 Press the Res reset button to clear the memory 2 Press and hold the time run mode button while setting the time a Press the h button to set the hours b Press the m button to set the minutes c Repeatedly press the Day button to select the day of the week 1 7 Monday Sunday 3 When set correctly the colon between the hours and minutes flashes 4 To reset for daylight savings time a Press the 1h button one time in the spring to advance the time one hour b Press 1h one time in the fall to set the time back one hour Notes The time and the day of the week must be set before programming the Timer The Timer has sufficient back up power to maintain the time and program settings for up to four days Programming 1 2 To set the T
13. ncy source contacts closed auxiliary contact TSE 1NO closes to power the pilot light Control Module LED Indicators EMERGENCY FREQUENCY MONITOR LED Green This LED is on when the emergency source frequency is within the operating range EMERGENCY VOLTAGE MONITOR LED Red This LED is on when the emergency source voltage is above the pick up level ENGINE RUNNING UNLOADED LED Red This LED is on when the engine generator is running during the cool down interval NORMAL VOLTAGE MONITOR LED Green This LED is on when the normal source voltage is above the pick up level RETRANSFER TO NORMAL SOURCE LED Red This LED is on during the RETRANSFER TO NORMAL time delay after the normal source voltage rises above the pick up level TRANSFER TO EMERGENCY SOURCE LED Red This LED is on during the TRANSFER TO EMERGENCY time delay after the emergency source voltage and frequency is above the pick up level Time Delays ENGINE RUNNING UNLOADED TIME DELAY This time delay is provided to allow the engine generator to run for a cool down period after retransfer to the normal source At the end of this period the engine control relay contacts activate to shutdown the engine generator OVERRIDE MOMENTARY OUTAGES ON EMERGENCY SOURCE This time delay overrides a retransfer to the normal source when the emergency source voltage is low or drops out momentarily OVERRIDE MOMENTARY OUTAGES ON NORMAL SOURCE This time delay overrides transfer when the no
14. r damage timing sequence Check TCR and TR voltage and frequency TCR board fault relays Repair Replace TCR board Check board components with ohm meter Check for correct phase Correct line connections for sequence proper phase sequence Automatic transfer Mna mi Check PRM w ohm Replace PRM switch transfers when ATS Fire Pump Tieler d Check VOLTAGE Repair Replace C l ec epair Replace Contro Engine Start Relay Saree Onl aE PBT Replace MB relay Engine generator does and 2 not start j Control Modul fiuk Check Engine Start Repair Replace Control Contacts Module Engine generator Engine Start Relay continues to run fault unloaded Relay circuit fault Phase Rotation Check relay on Control Repair Replace Control Module Module 7 0 Transfer Control Relay Board Refer to schematic 49271 500 The primary purpose of the Transfer Control Relay board is to control the operation of the switching mechanism The board also has the isolation switch alarm circuit and relays Page 12 of 16 Pages Transfer Switch Components 1 Transfer Control Relay Controls whether the automatic transfer switch is in the normal or the emergency position De energized automatic transfer switch in Normal position Energized automatic transfer switch in Emergency position 2 Timer circuit not used on assembly 101 and 104 This circuit determines how long the automatic transfer switch stays in the neutral position Jumper JMP1 se
15. rams are provided as part of the drawing packet supplied with each transfer switch Refer to Bulletin 1000 for information about one year parts and labor warranty Page 16 of 16 Pages
16. rce voltage is restored the normal source electronic control initiates engine starting of the generator set and or activates the emergency source electronic control The engine control relay is a 12 VDC latching relay on the Control Module The customer connections for the engine start contacts are on PTB1 located on the left side of the transfer switch mounting panel Refer to the Field Connections Wiring Diagram posted on the inside of the cabinet door and in the drawing packet for customer connections The emergency source electronic control monitors the emergency source for the acceptable voltage and frequency pick up levels When both the voltage and frequency of the emergency source are verified 24 VDC from the Control Module energizes the TCR Transfer Control Relay The normally open contacts of the TCR close to power the transfer switch switching mechanism via emergency transformer XFMR2 After the emergency source contacts close auxiliary contacts TSEb1 open to disconnect power to the switching mechanism Transfer switches with the NEUTRAL POSITION TIME DELAY stop in the neutral position After the adjustable time delay expires Q1 on the TCR board turns on to energize the TR relay The TR relay contacts close to re connect power to the switching mechanism to complete the transfer An EMERGENCY OVERRIDE ON MOMENTARY OUTAGE time delay is provided to override momentary voltage dips preventing the transfer switch from retransferring to the no
17. rmal source If the emergency source voltage is restored above the pick up setting within the delay period the delay timer is reset Retransfer to Normal Source When the Control Module detects that the normal source voltage rises above the pick up settings the timing sequence starts for retransfer to the normal source The RETRANSFER TO THE NORMAL time delay starts to allow the normal source to stabilize before retransfer If the normal source does not meet pick up requirements the delay timer is reset At the end of this delay the TCR is de energized The normally closed contacts of the TCR close The switching mechanism is then powered by 120 V from the normal transformer XFMR1 through the TCR relay contacts After the normal source contacts close auxiliary contact TSNb1 opens to disconnect power to the switching mechanism Transfer switches with the NEUTRAL POSITION TIME DELAY stop in the neutral position After the adjustable time delay expires the TR contacts close to complete transfer Page 6 of 16 Pages Transfer Switch 5 0 Standard and Optional Features Standard Features The following standard features are provided with the LX 450 automatic transfer switch Indicating lights NORMAL PL1 Green When the transfer switch is in the normal position normal source contacts closed auxiliary contact TSN 1NO closes to power the pilot light EMERGENCY PL2 Red When the transfer switch is in the emergency position emerge
18. rmal source voltage is low or drops out momentarily RETRANSFER TO NORMAL This time delay allows the normal source to stabilize before retransfer TRANSFER TO EMERGENCY This time delay allows the emergency source to stabilize before retransfer Page 7 of 16 Pages Transfer Switch Auxiliary Contacts Auxiliary contacts TSNa3 a4 and TSEa3 a4 are available for remote alarms pilot lights or other applications These contacts are pre wired for customer connections to PTB1 7 through PTB1 12 The contacts are rated at 10 A 125 250 VAC Manual Disconnect Switch The MDS Manual Disconnect Switch is mounted on the TRC board This switch isolates the power source to the switching mechanism Then the automatic transfer switch can only be operated manually with the handle CAUTION Disconnect normal and emergency power sources before using handle to transfer the contacts TEST push button The TEST push button simulates a loss of power from the normal source and causes the Control Module to initiate transfer to the emergency source Optional Features The items described in this section are a few of the optional features available with the LX 450 automatic transfer switch Contact the local Hubbell representative for additional options desired for an application Refer to the job schematic and wiring diagrams for these and other features BYPASS RETRANSFER TO NORMAL push button S1 This option is standard for combination Fire Pump
19. sfer switch showing one phase Page 3 of 16 Pages Transfer Switch 2 0 Specifications and Certifications Specifications Switch Mechanism Solenoid Actuation Short Circuit Ratings of Transfer Switches RMS Symmetrical Amperes 100 A 42 000 200 A 50 000 When protected by 260 400 600 A 65 000 a circuit breaker 800 1000 1250 A 85 000 Control Voltage 120 VAC Pick up Voltage 90 of normal source voltage 90 of emergency source voltage Drop out Voltage 84 of normal source voltage 84 of emergency source voltage Auxiliary Contacts 10 A 125 250 VAC Note Time delay settings and voltage pick up and drop out levels are set at the factory and should not be changed without consulting the factory Certifications Hubbell s Automatic transfer switches meet the requirements for all of the certifications listed below UL 1008 Standard for Safety for automatic transfer NEC Article 517 Health Care facilities switches NEC Article 702 Optional Standby Systems NEC Article 701 Legally Required Standby Systems LX 450 only NFPA 20 Installation of Fire Pumps 3 0 Installation Refer to the transfer switch nameplate to ensure that the voltage current and horsepower ratings are compatible with the load Refer to the receiving handling storage installation and inspection procedures in the Instruction Manual that accompanies the combination Fire Pump Controller and automatic transfer switch Many of the procedures in the instal
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