CUMMINS OTPCA, OTPCF, OTPCB, OTPCE, OTPCG Operator's Manual
...
OperatorOperator ManualManual
Generator Set
40-4000 Amps
OTPCA (Spec A)
OTPCB (Spec A)
OTPCC (Spec A)
OTPCD (Spec A)
OTPCE (Spec A-C)
OTPCF (Spec A-B)
OTPCG (Spec A-B)
OTPCH (Spec A-B)
OTPCJ (Spec A)
English
Original Instructions 5-2013 962-0132 (Issue 6)
Table of Contents
1. SAFETY PRECAUTIONS .............................................................................................................. 1
1.1 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death ....................... 1
1.2 General Precautions ............................................................................................................... 1
2. INTRODUCTION............................................................................................................................ 3
2.1 Operator Manual..................................................................................................................... 3
2.2 How to Obtain Service............................................................................................................ 3
2.3 Model Identification................................................................................................................. 4
2.4 Transfer Switch Application .................................................................................................... 4
2.5 Specifications .......................................................................................................................... 5
2.5.1 Model OTPC ................................................................................................................ 5
2.6 Automatic Transfer Switch Typical Function........................................................................... 6
2.6.1 Open Transition with Sync Check................................................................................ 6
2.6.2 Programmed Transition................................................................................................ 6
2.6.3 Closed Transition ......................................................................................................... 6
2.7 Utility-to-Generator Set Operation .......................................................................................... 6
2.8 Utility-to-Utility Operation ........................................................................................................ 6
2.9 Generator-to-Generator Operation ......................................................................................... 7
2.9.1 Prime Power (Plant-to-Plant) Operation ...................................................................... 8
2.9.2 Dual Stand-By Operation ............................................................................................. 9
2.10 Control Level 1 and Level 2................................................................................................ 10
3. DESCRIPTION............................................................................................................................. 11
3.1 Cabinet.................................................................................................................................. 11
3.2 Protective Relay.................................................................................................................... 11
3.3 Transfer Switch Components................................................................................................ 14
3.3.1 Contact Assemblies ................................................................................................... 14
3.3.2 Linear Actuator........................................................................................................... 14
3.3.3 Motor Disconnect Switch (150-1000 Amp Switches)................................................. 15
3.3.4 Motor Disconnect Switch (1200-4000 Amp Switches)............................................... 15
3.3.5 Auxiliary Contacts ...................................................................................................... 15
3.4 Electronic Control System..................................................................................................... 15
3.4.1 Time Delays ............................................................................................................... 16
3.4.2 System Sensors......................................................................................................... 18
3.4.3 Transfer Modes.......................................................................................................... 24
3.4.4 Front Panel Test - Sequence of Events..................................................................... 29
3.5 Options.................................................................................................................................. 39
3.5.1 Battery Charger Options ............................................................................................ 39
3.5.2 PowerCommand Network Interface Option ............................................................... 47
3.5.3 Load Sequencing Option ........................................................................................... 51
3.5.4 Load Current and Power Sensor Option.................................................................... 51
3.5.5 Source 1 and Source 2 Connected Relays................................................................ 52
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3.5.6 Source 1 and Source 2 Available Relays .................................................................. 52
3.5.7 Test or Exercise Active Relay .................................................................................... 52
3.5.8 Load Shed Relay ....................................................................................................... 52
3.5.9 Fail to Transfer/Retransfer Relay............................................................................... 52
3.5.10 Fail to Synchronize Relay ........................................................................................ 52
3.5.11 Fail to Disconnect Relay .......................................................................................... 52
3.5.12 Elevator Pre-Transfer Delay Relay .......................................................................... 53
3.5.13 Not-in-Auto Relay..................................................................................................... 53
3.6 Control Panel (PowerCommand Control) ............................................................................. 53
3.6.1 Bar Graph Meter Panel.............................................................................................. 53
3.6.2 Switch Panel .............................................................................................................. 54
3.6.3 Digital Display ............................................................................................................ 55
3.6.4 Time Delay Glossary.................................................................................................. 56
4. OPERATION ................................................................................................................................ 59
4.1 Manual Operation ................................................................................................................. 59
4.1.1 Manual Operation - 40 to 1000 Amp Switches .......................................................... 59
4.1.2 Manual Operation - 1200 to 4000 Amp Switches ...................................................... 59
4.2 Automatic Operation ............................................................................................................. 61
4.2.1 Motor Disconnect Switch ........................................................................................... 61
4.3 System Testing ..................................................................................................................... 62
4.3.1 Generator Set Manual Start Test ............................................................................... 62
4.3.2 With-Load Standby System Test ............................................................................... 62
4.4 Generator Set Exercise......................................................................................................... 62
4.5 Planned Maintenance ........................................................................................................... 63
5. DIGITAL DISPLAY MENU SYSTEM............................................................................................ 65
5.1 Main Menus .......................................................................................................................... 65
5.2 Password and Setup Menus................................................................................................. 65
5.3 Navigation ............................................................................................................................. 65
5.4 Main Menu Descriptions ....................................................................................................... 66
5.4.1 First Main Menu ......................................................................................................... 66
5.4.2 Second Main Menu .................................................................................................... 68
5.4.3 Third Main Menu ........................................................................................................ 69
5.4.4 Setup Menu Navigation and Description ................................................................... 72
6. WIRING CONSIDERATIONS FOR CLOSED TRANSITION SWITCHES ................................... 85
6.1 Wiring Considerations for Closed Transition Transfer Switches .......................................... 85
6.2 Re-transfer and transfer inhibit functions.............................................................................. 85
6.3 Fail to disconnect .................................................................................................................. 87
7. TROUBLESHOOTING ................................................................................................................. 89
7.1 Control Module LED Indicators and Switch .......................................................................... 89
7.2 Fault Flash-Out ..................................................................................................................... 90
7.3 Exerciser Enable/Disable Switch .......................................................................................... 90
7.4 Troubleshooting Transfer Switch With the Digital Display .................................................... 90
7.4.1 Fault Events ............................................................................................................... 91
ii 962-0132 (Issue 6)
5-2013 Table of Contents
7.5 Fault Event Definitions .......................................................................................................... 92
7.5.1 Controller Checksum Error ........................................................................................ 92
7.5.2 Low Controller Battery ............................................................................................... 92
7.5.3 ATS Fail to Close: Transfer ....................................................................................... 92
7.5.4 ATS Fail to Close: Re-Transfer.................................................................................. 92
7.5.5 Battery Charger Malfunction ...................................................................................... 92
7.5.6 Network Battery Low .................................................................................................. 92
7.5.7 Network Communications Error ................................................................................. 93
7.6 15/12-Amp Battery Charger Troubleshooting and Faults ..................................................... 93
7.6.1 Clearing Faults........................................................................................................... 93
7.6.2 Fault Alarm Output Connector ................................................................................... 93
7.7 Code 101 – Source 1 Connected (Event)............................................................................. 94
7.8 Code 102 – Source 1 Available (Event) ............................................................................... 94
7.9 Code 103 – Source 2 Connected (Event)............................................................................. 94
7.10 Code 104 – Source 2 Available (Event) ............................................................................. 95
7.11 Code 105 – Emergency Start A (Event) ............................................................................. 95
7.12 Code 106 – Test Start A (Event) ........................................................................................ 96
7.13 Code 107 – Emergency Start B (Event) ............................................................................. 96
7.14 Code 108 – Test Start B (Event) ........................................................................................ 97
7.15 Code 109 – Time Delay Engine Start A (Event) ................................................................. 97
7.16 Code 111 – Time Delay Engine Start B (Event) ................................................................. 98
7.17 Code 112 – Time Delay Transfer (Event) ........................................................................... 98
7.18 Code 113 – Time Delay Retransfer (Event) ....................................................................... 99
7.19 Code 114 – Engine Cool-Down A (Event) ........................................................................ 100
7.20 Code 115 – Program Transition (Event)........................................................................... 100
7.21 Code 116 – Transfer Pending (Event).............................................................................. 100
7.22 Code 117 – Test in Progress (Event) ............................................................................... 101
7.23 Code 118 – Exercise Active (Event)................................................................................. 101
7.24 Code 119 – Sync Check (Event) ...................................................................................... 102
7.25 Code 121 – S1 Under Voltage (Event) ............................................................................. 102
7.26 Code 122 – S1 Over Voltage (Event) ............................................................................... 103
7.27 Code 123 – S1 Frequency Fail (Event) ............................................................................ 103
7.28 Code 124 – S1 Loss Phase (Event) ................................................................................. 103
7.29 Code 125 – S1 Imbalance Fail (Event)............................................................................. 104
7.30 Code 126 – S2 Under Voltage (Event) ............................................................................. 104
7.31 Code 127 – S2 Over Voltage (Event) ............................................................................... 105
7.32 Code 128 – S2 Frequency Fail (Event) ............................................................................ 105
7.33 Code 129 – S2 Loss Phase (Event) ................................................................................. 106
7.34 Code 131 – S2 Imbalance Fail (Event)............................................................................. 106
7.35 Code 132 – Phase Rotation Failure (Event) ..................................................................... 107
7.36 Code 133 – Motor Disconnect (Event) ............................................................................. 107
7.37 Code 134 – Load Shed (Event) ........................................................................................ 107
7.38 Code 135 – Transfer Inhibit (Event) ................................................................................. 108
7.39 Code 136 – Retransfer Inhibit (Event) .............................................................................. 108
7.40 Code 137 – Bypassed to S1 (Event) ................................................................................ 109
7.41 Code 138 – Bypassed to S2 (Event) ................................................................................ 109
962-0132 (Issue 6) iii
Table of Contents 5-2013
7.42 Code 139 – Not in Auto (Fault) ......................................................................................... 110
7.43 Code 141 – Service Tool (Event) ..................................................................................... 110
7.44 Code 143 – Sync Enable (Event) ..................................................................................... 111
7.45 Code 144 – Speed Adjust (Event) .................................................................................... 111
7.46 Code 145 – Fail to Sync (Event)....................................................................................... 111
7.47 Code 146 – Sequencer Output 1-8 (Event) ...................................................................... 112
7.48 Code 155 – Network Wink (Event) ................................................................................... 112
7.49 Code 156 – Common Alarm A (Event) ............................................................................. 113
7.50 Code 157 – Common Alarm B (Event) ............................................................................. 113
7.51 Code 158 – Loss of Power (Event)................................................................................... 114
7.52 Code 159 – TD Stop B (Event) ......................................................................................... 114
7.53 Code 161 – High Neutral Amps (Event) ........................................................................... 115
7.54 Code 162 –Preferred Source 1 (Event) ............................................................................ 115
7.55 Code 163 –Preferred Source 2 (Event) ............................................................................ 115
7.56 Code 164 – Source 1 Stopped (Event)............................................................................. 116
7.57 Code 165 – Source 2 Stopped (Event)............................................................................. 116
7.58 Code 167 – Control Lockout (Event) ................................................................................ 116
7.59 Code 168 – Panel Lock (Event)........................................................................................ 117
7.60 Code 169 – Max Parallel Time Exceeded (Event)............................................................ 117
7.61 Code 441 – Low Controller Battery (Event) ...................................................................... 118
7.62 Code 597 –Battery Charger Malfunction (Fault)............................................................... 118
7.63 Code 1113 – ATS Fail to Close: Transfer (Fault) ............................................................. 119
7.64 Code 1114 – ATS Fail to Close: RE-Transfer (Fault) ....................................................... 119
7.65 Code 1121 – ATS Fail to Disconnect (Fault).................................................................... 120
7.66 Code 1452 – Fail to Close S2 (Fault) ............................................................................... 121
7.67 Code 1453 – Failed to Open S2 (Fault)............................................................................ 121
7.68 Code 1468 – Network Communications Error (Fault)....................................................... 122
7.69 Code 2396 – Failed to Close S1 (Fault) ........................................................................... 122
7.70 Code 2397 – Fail to Open S1 (Fault)................................................................................ 123
iv 962-0132 (Issue 6)
1 Safety Precautions
This manual includes the following symbols to indicate potentially dangerous conditions. Read
the manual carefully and know when these conditions exist. Then, take the necessary steps to
protect personnel and the equipment.
DANGER
This symbol warns of immediate hazards that will result in severe personal
injury or death.
WARNING
This symbol refers to a hazard or unsafe practice that can result in severe personal
injury or death.
CAUTION
This symbol refers to a hazard or unsafe practice that can result in personal injury or
product or property damage.
1.1 Electrical Shock and Arc Flash Can Cause Severe Personal Injury or Death
High voltage in transfer switch components presents serious shock hazards that can result in
severe personal injury or death. Read and follow these suggestions:
• The Operator must always keep the transfer switch cabinet closed and locked.
• Make sure only authorized personnel have the cabinet keys.
• All service and adjustments to the transfer switch must be performed only by an electrician
or authorized service representative.
Whenever closed transition is used, approval to parallel with the local electric utility
must be obtained.
1.2 General Precautions
Refer to NFPA 70E Standard for Electrical Safety in the Workplace to be sure the proper
personal protective equipment (PPE) is worn around this product.
Follow these guidelines while working on or around electrical equipment.
• Place rubber insulated mats on dry wood platforms over metal or concrete floors when
working on any electrical equipment.
NOTICE
• Do not wear damp clothing (particularly wet shoes) or allow skin surfaces to be damp when
handling any electrical equipment.
962-0132 (Issue 6) 1
1. Safety Precautions 5-2013
• Remove all jewelry when working on electrical equipment.
• Wear safety glasses whenever servicing the transfer switch.
• Do not smoke near the batteries.
• Do not work on this equipment when mentally or physically fatigued, or after consuming
alcohol or any drug that makes the operation of equipment unsafe.
WARNING
Incorrect service or replacement of parts can result in death, severe personal injury,
and/or equipment damage. Service personnel must be qualified to perform electrical
and/or mechanical service.
2 962-0132 (Issue 6)
2 Introduction
2.1 Operator Manual
This manual covers models produced under the Cummins®and Cummins Power Generation
(CPG) brand names.
The information contained within the manual is based on information available at the time of
going to print. In line with Cummins Power Generation policy of continuous development and
improvement, information may change at any time without notice. The users should therefore
make sure that before commencing any work, they have the latest information available. The
latest version of this manual is available on QuickServe Online
(https://qsol.cummins.com/info/index.html).
This Operator Manual provides information necessary for the operation of the transfer switch(es)
identified on the cover of this manual. The transition capabilities of the transfer switch(es) are
identified in the following sections.
2.2 How to Obtain Service
When the transfer switch requires servicing, contact your nearest Cummins Power Generation
distributor. Factory-trained Parts and Service representatives are ready to handle all of your
service needs.
To contact your local Cummins Power Generation distributor in the United States or
Canada:
• Call 1-800-888-6626 (this automated service utilizes touch-tone phones only).
• Select Option 1 (press 1) and you will be automatically connected to the distributor nearest
you.
If you are unable to contact a distributor using the automated service, consult the Yellow
Pages. Typically, distributors are listed under one of the following:
• Generators-Electric
• Engines-Gasoline
• Engines-Diesel
• Recreational Vehicles-Equipment
• Parts and Service
For outside North America:
• Call Cummins Power Generation at 1-763-574-5000, 7:30 AM to 4:00 PM Central Standard
Time, Monday through Friday.
OR
• Send a fax to Cummins Power Generation using the fax number, 1-763-574-5298.
When contacting your distributor, always supply the complete model, specification and serial
number as shown on the generator set nameplate.
962-0132 (Issue 6) 3
2. Introduction 5-2013
2.3 Model Identification
If the transfer switch ever needs to be serviced, the distributor will need this information in order
to properly identify your unit from the many types manufactured:
• Model No. (Product Model)
• Serial No. (Product Serial Number)
• Spec. (Product Specification Letter)
FIGURE 1. CONTROL NAMEPLATE
2.4 Transfer Switch Application
Transfer switches are an essential part of a building's standby or emergency power system. The
utility line (normal power), is backed up by a generator set (emergency power). The transfer
switch automatically switches the electrical load from one source to the other.
4 962-0132 (Issue 6)
5-2013 2. Introduction
If utility power is interrupted, the load is transferred to the generator set (genset). When utility
power returns, the load is retransferred to the utility. The transfer and retransfer of the load are
the two most basic functions of a transfer switch.
2.5 Specifications
2.5.1 Model OTPC
Transfer Switch Model OTPC Specifications:
Model Amps Cabinet Types Util-to-Gen Gen-to-Gen Util-to-Gen Dual Plant-to- Transfer
(Level 1 & (Level 2)
2) (Prime
OTPCA 40 All Amps: OT
70 4, 3R, 1, 12, 4x X X X X PT
125
OTPCB 150 150-225 Amp OT
OTPCC 300 All Amps: OT
OTPCD 800 All Amps (3 & OT
1000 PT
OTPCE 1000 All Amps: OT
1200 1, 3R, 12, 4, 4x X X X X X PT
OTPCF 1600 1, 3R, 12, 4 OT
OTPCG 2000 1, 3R, 12, 4 OT
OTPCH 3000 1, 3R OT
(3 & 4-Pole):
225 PT
1, 3R, 12, 4x
260
150-225 Amp
(3 pole):
4
260 Amp (3 &
4-Pole):
1, 3R, 12, 4x
260 Amp (3
pole):
4
400 1, 3R, 12, 4, 4x X X X X PT
600
4-Pole):
1, 3R, 12, 4x
All Amps (3Pole):
4
X X X X
X X X X
X X X X X PT
X X X X X PT
X X X X X PT
& Util-to- Standby Plant Modes
Util
(Level 1 & Power)
2)
CT
CT
CT
CT
962-0132 (Issue 6) 5
2. Introduction 5-2013
OTPCJ 4000 1, 3R OT
X X X X X PT
CT
2.6 Automatic Transfer Switch Typical Function
Automatic transfer switches perform the basic function of transferring the load to the available
power source. The controller monitors each source for allowable voltage and frequency range.
The transfer switch(es) identified on the cover of this manual are designed for each, all or a
combination of the following applications (If you are unsure which of these your transfer switch
uses, refer to the Specifications section of this manual):
2.6.1 Open Transition with Sync Check
Open transition with sync check executes an open transition (OT) transfer when both sources of
power are within specified tolerances of frequency, voltage and relative phase difference. If both
sources meet the tolerances, a fast transfer occurs.
2.6.2 Programmed Transition
Programmed transition executes a programmed transition (PT) transfer by disconnecting the
load from the source of power, pausing in the neutral position of the transfer switch (between
switched positions) to allow transient voltages from the load to diminish, and then the load is
switched to the other source.
2.6.3 Closed Transition
Closed transition executes a load transfer by momentarily paralleling both sources (a maximum
of 100ms) before switching sources.
2.7 Utility-to-Generator Set Operation
In utility-to-generator set applications, the transfer switch performs the following functions:
1. Senses the interruption of the Source 1 power (Utility).
2. Sends a start signal to the generator set (Source 2).
3. Transfers the load to the Source 2 power.
4. Senses the return of Source 1 (Utility).
5. Retransfers the load to Source 1.
6. Sends a stop signal to the generator set.
2.8 Utility-to-Utility Operation
In utility-to-utility applications, the transfer switch performs the following functions:
1. Senses the interruption of the Source 1 power (Utility).
2. Transfers the load to the Source 2.
3. Senses the return of Source 1 (Utility).
6 962-0132 (Issue 6)
5-2013 2. Introduction
4. Retransfers the load to Source 1.
2.9 Generator-to-Generator Operation
In generator-to-generator applications, there are two possible configurations.
• Prime Power (Plant-to-Plant) Operation - Two generator sets provide all of the power
(utility power is not available).
• Dual Standby - Two generator sets are used to back up utility power.
No. Description No. Description
1 Generator set B 6 Standby start signal
2 Utility 7 Utility-to-Gen ATS
3 Over current protective device 8 Generator set A
4 Load 9 Gen-to-Gen configuration in Prime Power mode
5 Gen-to-Gen ATS 10 Gen-to-Gen configuration in Dual Standby mode
FIGURE 2. GENERATOR-TO-GENERATOR CONFIGURATION IN PRIME POWER AND DUAL
STANDBY MODES
962-0132 (Issue 6) 7
2. Introduction 5-2013
2.9.1 Prime Power (Plant-to-Plant) Operation
In prime power applications, utility power is not available. The system includes one transfer
switch and two generator sets. One generator set is always running and supplying power to the
load while the other generator set is the backup generator set. An external power supply is not
needed in this application.
2.9.1.1 Preferred Source Selection
Under normal operation, one genset is designated as the preferred source and supplies power
to the load. The second genset is the backup power source. If the preferred genset fails, the
backup genset starts and the transfer switch transfers the load to the backup genset.
At any time, the PC service tool or the Test sub-menu can be used to designate either genset
(Source 1 or Source 2) as the preferred genset. The Preferred Source menu is included in the
Test submenus.
If the preferred genset is changed and the backup genset becomes the preferred genset, the
transfer switch transfers the load to the new preferred genset when it becomes available. The
unit that is carrying the load is always considered the preferred source.
FIGURE 3. PREFERRED SOURCE SUBMENU
2.9.1.2 Automatic Changeover
The transfer switch can be set up to change the preferred source automatically by enabling the
changeover timer. The Time Delay submenus under Setup or the PC service tool can be used
to enable the changeover timer and specify a changeover delay time period. The Changeover
menus are included in the Time Delay submenus.
The automatic changeover timer automatically changes the preferred source and transfers the
load to the new preferred genset after a TDEN time delay. After the transfer is complete, the
control initiates a cool-down period (TDEC) on the old preferred genset before shutting it down.
The old preferred genset is now the new backup genset. The changeover timer is now timing for
the next changeover and the cycle continues as long as the changeover timer is enabled.
8 962-0132 (Issue 6)
5-2013 2. Introduction
FIGURE 4. CHANGEOVER SUBMENUS
2.9.2 Dual Stand-By Operation
In dual stand-by applications, utility power is available. The system includes two transfer
switches (a Utility-to-Generator ATS and a Generator-to-Generator ATS) and two generator
sets. Utility power supplies power to the load and both generator sets are backup generator
sets.
Under normal operation, the utility is supplying power to the load through the lead transfer
switch. The lead transfer switch is a utility-to-generator set switch. The two generator sets are
connected to the generator set-to-generator set transfer switch. The load side of this switch is
connected to the generator set side of the lead transfer switch.
Upon loss of utility power to the lead transfer switch, a standby start signal is sent to the
generator set-to-generator set transfer switch to start the preferred generator set. When the lead
transfer switch senses generator voltage, it transfers the load to that generator set. If the
preferred generator set fails to start, a signal is sent to the backup generator set to start. The
PC Service tool or the Test sub-menu on the generator set-to-generator set transfer switch can
be used to set the preferred source.
If the Stand-By Start is inactive, upon initial power–up (or reset), or during software initialization,
the transfer switch control will not start either generator set. When a Stand-By Start command is
received by the Generator-to-Generator ATS from a Utility-to-Generator ATS (or other device),
the preferred generator set immediately starts. If the preferred generator set does not start, the
control starts the backup generator set. The load is connected to the generator set when it
becomes available.
If the preferred generator set becomes available while the backup generator set is active, a time
delay re-transfer (TDEN) period is initiated and the load is re-transferred back to the preferred
generator set. A time delay cool-down (TDEC) period is initiated before turning off the backup
generator set. When the Stand-By Start becomes deactivated, a TDEC period is initiated and
the active generator is turned off.
962-0132 (Issue 6) 9
2. Introduction 5-2013
2.9.2.1 Preferred Source Selection
Under normal operation, one genset is designated as the preferred source and the second
genset is designated as the backup power source. If both the utility power and the preferred
genset fails, the backup genset starts and the genset-to-genset transfer switch transfers the
load to the backup genset.
At any time, the PC service tool or the Test sub-menu on the genset-to-genset transfer switch
can be used to designate either genset (Source 1 or Source 2) as the preferred genset. If the
preferred genset is changed and the backup genset becomes the preferred genset, the transfer
switch transfers the load to the new preferred genset if it is needed and when it becomes
available.
2.9.2.2 Alternating Preferred Source
In an attempt to keep the running time equally distributed between both generator sets, the
control can be set to alternate between the generator sets when utility power fails. The selected
preferred generator set starts with the first power outage. The second power outage starts the
backup generator set, which now becomes the preferred generator set. Upon subsequent
outages, the preferred generator set alternates.
Only utility outages and tests or exercises initiated at the lead transfer switch result in the
generator sets being alternated. The designated preferred generator set will not change if it fails
and the backup generator set takes over the load. This alternating preferred source can only be
enabled with the PC Service tool. When enabled, a generator set can be designated as the
preferred source for a maximum of two weeks. Time adjustments can be made in one-hour
increments with the Test submenu.
2.10 Control Level 1 and Level 2
Two controls are available. The type of power source switched and the desired features
determine the control levels available.
The control board level can be viewed, using the digital display. This menu is included in the
About submenus.
NOTICE
The digital display comes standard with level 2 controls and is optional with level 1
controls.
FIGURE 5. CONTROL LEVEL SUBMENU
10 962-0132 (Issue 6)
3 Description
3.1 Cabinet
Cabinets are available in various configurations that meet UL and National Electrical
Manufacturer's Association (NEMA) requirements. Each cabinet includes an identification label.
The standard cabinet offerings are:
• Type 1 Indoor - general purpose
• Type 3R Outdoor - rainproof
• Type 4 Outdoor - watertight
• Type 4X Outdoor - watertight, stainless steel
• Type 12 Indoor - dust tight
3.2 Protective Relay
This section describes the solid state relays designed for use in single- or three-phase systems
to protect equipment against overpower and/or under-power conditions.
To increase the level of protection in our closed transition switches we have included a lock out
relay (86) that can trip from two different signals. It can trip from the K32R directional relay when
it senses reverse power is exported to utility or when the 62PL parallel timer has detected that
two sources have been connected for more than the predefined time (not the same as
“Maximum Parallel Timer" in the digital board).
The 86 lockout relay trips when the internal 24VDC relay coil is energized, and it is always
required to manual reset the relay. NC and NO dry contacts are provided for customer wiring
which are rated for 20A 600V. Factory settings for the 62PL are 1 and 3 closed (ON), 2 and 410 open (OFF), for 500mS delay.
962-0132 (Issue 6) 11
3. Description 5-2013
No. Description No. Description
1 Lockout relay 2 Rectifier
3 Transformer 4 Relay
5 Terminal blocks
FIGURE 6. RELAY INSTALLATION M036/M038
12 962-0132 (Issue 6)
5-2013 3. Description
No. Description No. Description
1 Lockout relay 2 Rectifier
3 Transformer 4 Relay
5 Terminal Blocks
FIGURE 7. RELAY INSTALLATION M036/M038
962-0132 (Issue 6) 13
3. Description 5-2013
No. Description No. Description
1 Transformer 2 Relay
3 Rectifier 4 Lockout relay
5 Terminal blocks
FIGURE 8. RELAY INSTALLATION M036/M038
3.3 Transfer Switch Components
The transfer switch opens and closes the contacts that transfer the load between the power
sources (Source 1 and Source 2). The switch is mechanically interlocked to prevent
simultaneous closing to both power sources (except in switches capable of closed transitions).
3.3.1 Contact Assemblies
The automatic transfer switch has either three or four poles. Three pole transfer switches are
provided with a neutral bar. The contact assemblies make and break the current flow. When
closed to either power source the contacts are mechanically held. A mechanical interlock
prevents them from closing to both power sources at the same time.
3.3.2 Linear Actuator
The linear actuator moves the contact assemblies between the contacts of both power sources.
Linear actuator operation is initiated automatically by the transfer switch control. Manual
operation of the switch is also possible.
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5-2013 3. Description
3.3.3 Motor Disconnect Switch (150-1000 Amp Switches)
Moving the Draw out lever to the Release position disables the linear actuator. The Not In Auto
indicator on the front panel will light and the display indicates a motor disconnect event.
3.3.4 Motor Disconnect Switch (1200-4000 Amp Switches)
The Motor Disconnect toggle switch on the accessory control plate enables and disables the
linear actuator.
• Placing the switch in the AUTO position enables the linear actuator.
• Placing the switch in the OFF position disables the linear actuator. When placed in the
OFF position, the Not In Auto indicator on the front panel will light and the display indicates
a motor disconnect event.
3.3.5 Auxiliary Contacts
Auxiliary contacts are provided on the utility and genset sides of the transfer switch. They are
actuated by operation of the transfer switch during transfer and retransfer. The utility auxiliary
contact switch is actuated when the transfer switch is connected to the utility. The genset
auxiliary contact switch is actuated when the transfer switch is connected to the genset. The
auxiliary contacts have current ratings of 10 amperes at 250 VAC. The contacts are wired to
terminal block TB1.
FIGURE 9. AUXILIARY CONTACTS
3.4 Electronic Control System
This section describes the standard and optional components of the electronic control system.
WARNING
Improper calibration or adjustment of electronic control modules can cause death, severe
personal injury, and equipment or property damage. Calibration and adjustment of these
components must be performed by technically qualified personnel only.
For further information regarding installation, calibration and adjustment of these components,
refer to the:
• Installation Manual (shipped with the product)
• Service Manual (available through your distributor)
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3. Description 5-2013
WARNING
Accidental actuation of the linear motor could cause severe personal injury. Before making any
adjustments, place the Motor Disconnect Switch in the OFF position. Return the switch to the
Auto position after adjustments are completed.
WARNING
AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that
can cause severe personal injury or death. When the cabinet door is open, use extreme caution
to avoid touching electrical contacts with body, tools, jewelry, clothes, hair, etc.
3.4.1 Time Delays
3.4.1.1 Time Delay Engine Start (TDES-A and TDES-B)
Time Delay Default: 3 seconds (for both TDES-A and TDES-B)
Adjustable: The value is set with the InPower service tool or the digital display.
• Adjustable from 0-15 seconds in 1 second increments on Level 1 controls.
• Adjustable from 0-120 seconds on Level 2 controls.
• Values up to 20 seconds are adjustable in 1 second increments.
• Values over 20 seconds are adjustable in 5 second increments.
Purpose: Prevents the generator set from starting during short power interruptions.
Sequence of Events: Timing begins at the Source 1 power interruption (or the preferred source
interruption on gen-to-gen units). If the duration of interruption exceeds the delay time, the
control system starts the generator.
NOTICE
For long engine start time delays (over 15 seconds) a remote battery source must be
used.
For Genset-to-Genset applications: TDES-A is the start time delay to start the Source 2 genset
and TDES-B is the start time delay to start the Source 1 genset.
For Utility-to-Utility applications: TDES-A and TDES-B are not available.
3.4.1.2 Time Delay Engine Cool-down (TDEC-A and TDEC-B)
Time Delay Default: 10 minutes
Adjustable: Adjustable from 0-30 minutes, in 1 minute increments. The value is set with the
InPower service tool or the digital display.
Purpose: Allows the generator set to cool without load before stopping.
Sequence of Events: Timing begins when the load is retransferred to Source 1 (or to the
preferred source on gen-to-gen units). At the end of the delay, the stop signal is sent to the
generator set. During this time delay, the generator set cools down without load before stopping.
For Genset-to-Genset applications: TDEC-A is the stop time delay to stop Source 2 genset and
TDEC-B is the stop time delay to stop Source 1 genset.
For Utility-to-Utility applications: TDEC-A and TDEC-B are not available.
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5-2013 3. Description
3.4.1.3 Time Delay Normal to Emergency (TDNE)
Time Delay Default: 5 seconds
Adjustable: Adjustable from 0-120 seconds, in 1 second increments. The value is set with the
InPower service tool or the digital display.
Purpose: Allows the generator set to stabilize before the load is applied.
Sequence of Events: Timing begins when:
• Source 2 voltage and frequency reaches the settings of the control.
• Preferred source voltage (on gen-to-gen units) and frequency reaches the settings of the
control.
• Preferred utility becomes available (on utility-to-utility units).
After the delay, the transfer switch transfers the load to Source 2.
3.4.1.4 Time Delay Emergency to Normal (TDEN)
Time Delay Default: 10 minutes
Adjustable: Configurable for 0 (disabled), 0.1, 5, 10, 15, 20, 25 or 30 minutes.
Purpose: Allows utility power to stabilize before retransfer. This delay also allows the generator
to operate under load for a minimum amount of time before transferring back to utility power.
Sequence of Events: Timing begins with the transfer switch connected to the generator and
after the utility becomes available following an outage (the green Utility Power Available LED is
lit). This time delay also starts when an active test or exercise period has ended. After the delay,
the transfer switch can retransfer the load to the utility power source.
• If the utility fails any time during this time delay, the control resets the timer and restarts it
once utility power becomes available.
• If the generator fails at any time during this time delay, the timer expires and the normal
retransfer sequence takes place.
• If the Override pushbutton is pressed or the Override input is grounded while the TDEN
timer is active, the TDEN timer immediately expires.
• The TDEN timer will not begin if a Retransfer Inhibit input is active.
3.4.1.5 Time Delay Elevator (TDEL)
Time Delay Default:0 seconds
Adjustable: Adjustable from 0-60 seconds, in 1 second increments. The value is set with the
InPower service tool or the digital display.
Purpose: Allows an elevator to come to a complete stop before the switch transfers.
Sequence of Events: Timing begins after the transfer or retransfer timing ends. TDEL only
times when transferring between two live sources.
3.4.1.6 Time Delay Programmed Transition (TDPT)
Time Delay Default:0 seconds
Adjustable: Configurable for 0 (disabled), 0.5, 1, 2, 3, 4, 6 or 10 seconds.
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3. Description 5-2013
Purpose: Allows the transfer switch to pause in the Neutral position for an adjustable period of
time whenever there is a transfer from one source to another.
• This intentional delay allows the residual voltage of an inductive load to sufficiently decay
before connecting it to another power source.
• This delay prevents potentially damaging voltage and current transients in the customer's
power system.
Sequence of Events: Timing begins whenever the transfer switch has disconnected from one
source and is in the Neutral position.
• If TDPT is set to zero, then the transfer switch transfers from one source to the other with
no neutral position delay.
• The control also detects if the transfer switch has disconnected from the first source before
connecting it to the second one.
• If there is a power source failure while the TDPT is active, the control only transfers to the
remaining active power source.
• The control does not terminate the TDPT timer if either source fails while the transfer
switch is in the Neutral position.
3.4.2 System Sensors
3.4.2.1 Under-Voltage Sensing
All controls include under-voltage sensors for Source 1 and Source 2.
Default Value:
• Pick-up: 90%
• Drop-out: 90% of the pick-up setting
Range:
• The pick-up range for a rising voltage is 85 to 100% of the nominal voltage set point.
• The under-voltage sensing range for a falling voltage (drop-out) is 75 to 98% of the pick-up
voltage setting.
Default Delay Time: 0.5 second
Adjustable: The adjustable range for the time delay period is 0.1 to 1.0 seconds in 0.1 second
increments. These values are set with the PC service tool or the digital display.
Sequence of Events:
• When a sensor detects a voltage below the set drop-out voltage for a period longer than
the time delay, it deems the voltage as unacceptable.
• When the sensor detects a voltage at or above the set pick-up point, it deems the voltage
as acceptable.
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5-2013 3. Description
FIGURE 10. UNDER-VOLTAGE SENSING SUBMENUS
3.4.2.2 Over-Voltage Sensing
All controls include over-voltage sensors for Source 1 and Source 2 that can be disabled and
not used. The over-voltage sensing feature is enabled by default.
Default Value:
• Over-voltage (drop-out) sensing range: 110%
• Pick-up range: 95%
Range:
• The over-voltage sensing range (drop-out) for a rising voltage is 105 to 135% of the
nominal voltage set point.
• The pick-up range for a falling voltage is 95 to 99% of the drop-out setting.
Default Delay Time: 3.0 seconds
Adjustable: The adjustable range for the delay time period is 0.5 to 120.0 seconds in 1 second
intervals. These values are set with the PC service tool or the digital display.
Sequence of Events:
• When a sensor detects a voltage above the set dropout voltage for a period longer than
the time delay, it deems the voltage as unacceptable.
• When the sensor detects a voltage at or below the set pickup point, it deems the voltage
as acceptable.
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3. Description 5-2013
FIGURE 11. OVER-VOLTAGE SENSING SUBMENUS
3.4.2.3 Frequency Sensing
All controls include frequency sensors for Source 1 and Source 2 that can be disabled and not
used.
Default Value:
• Nominal frequency: 60 Hz
• Frequency pick-up bandwidth: ±10%
• Frequency drop-out: 1% beyond pick-up bandwidth setting
Range:
• The nominal frequency can be set between 45.0 and 60.0 Hz in 0.1 Hz increments.
• The acceptable frequency bandwidth (pick-up) is ±5 to ±20% of the nominal frequency set
point.
• The drop-out frequency is 1 to 5% beyond the pick-up.
The frequency sensing feature is enabled by default.
Default Delay Time: 1.0 second
Adjustable: The adjustable range for the time delay period is 0.1 to 15 seconds.
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5-2013 3. Description
Sequence of Events:
• When a sensor detects a frequency outside the dropout bandwidth for a period longer than
the time delay, it deems the frequency as unacceptable.
• When the sensor detects a frequency within the pickup bandwidth, it deems the frequency
as acceptable.
FIGURE 12. FREQUENCY SUBMENUS
3.4.2.4 Voltage Imbalance Sensing
Three phase Level 2 controllers include a voltage imbalance sensor for both Source 1 and
Source 2. This feature informs the operator when there is significant voltage imbalance between
the phases of Source 1 or Source 2. This feature is used for equipment protection.
NOTICE
This sensor is inactive for single phase systems and indicates no failures. To prevent
nuisance faults, the setting can be increased up to 10% of the nominal voltage.
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3. Description 5-2013
This sensor can be enabled using the PC service tool or the digital display Setup submenus.
Default Value: 10%
Range:
• The maximum deviation from the average voltage is greater than a user-specified value
between 2 and 10% (dropout) of the average voltage in 1% increments.
• The pickup value is fixed at 10% of the dropout.
Default Delay Time: 10 seconds
Adjustable: The adjustable range for the time delay period for the imbalance sensor drop-out is
2 to 20 seconds.
Sequence of Events: A voltage imbalance is typically caused by severe single phase loading.
The sensor indicates a failure when the maximum deviation from the average voltage is greater
than a user-specified value (dropout) of the average voltage.
FIGURE 13. VOLTANGE IMBALANCE SENSOR SUBMENUS
3.4.2.5 Phase Rotation Sensing
Three phase Level 2 controllers include a phase rotation sensor.
This feature monitors the phase rotation of the source opposite from the connected source. Both
voltage sources must be applied in order to check phase rotation.
This feature protects against equipment damage by preventing transfer to a source that is out of
phase. This generally occurs on new installations or after storm damage or generator rewiring.
This feature is required in fire pump applications.
CAUTION
Level 1 controls do not support three-phase sensing on Source 2. Do not select the three-phase
option for the Source 2 Sensing adjustment with Level 1 controls, even if the system is three
phase. This setting will prevent Source 2 from becoming available.
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5-2013 3. Description
Default Value: Disabled
Adjustable: The adjustable range for phase rotation sensing is Enabled or Disabled (On or Off).
Sequence of Events: When the alternate source is out of phase rotation with the connected
source, transfer is inhibited.
FIGURE 14. PHASE ROTATION SENSING SUBMENU
3.4.2.6 Loss of Single Phase Sensing
Three phase Level 2 controllers include a loss of single phase sensor.
NOTICE
This sensor is inactive for single phase systems and indicates no failures.
This feature initiates a transfer from a source that has lost a single phase and prevents a
transfer to a source that has lost a single phase. This is generally caused by a single phase to
line ground or open.
This feature is mainly used to protect three phase devices, such as motors.
Default Value: Disabled
Adjustable: The adjustable range for loss of single phase sensing is Enabled or Disabled (On
or Off).
Sequence of Events: The controller indicates a fault when the relative phase angle between
any line-to-line phase angle drops to less than 90 degrees.
FIGURE 15. LOSS OF PHASE SENSING SUBMENU
3.4.2.7 Transfer Times
The controller senses and records the time it takes for the transfer switch to break from one
source and reconnect to the other source.
NOTICE
Transfer times are not recorded if Programmed Transition delay is in use.
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3. Description 5-2013
3.4.3 Transfer Modes
A transfer mode can be selected from the front panel digital display.
Since not all automatic transfer switches are configured the same, some may not have access
to all transition mode types. The transfer modes available on your transfer switch are identified
in the following section.
The transfer switch mode setting can be changed with the PC service tool or with the digital
display.
FIGURE 16. TRANSFER MODE SUBMENU
3.4.3.1 Available Transfer Modes
• Open Transition (OT) with Sync Check
• Programmed Transition (PT)
• Closed Transition (CT)
3.4.3.2 Open Transition with Sync Check
Open transition with sync check executes an open transition (OT) transfer when both sources of
power are within specified tolerances of frequency, voltage and relative phase difference. If both
sources meet the tolerances, a fast transfer occurs.
3.4.3.2.1 Transfer from Source 1 to Source 2 (OT)
This sequence begins with Source 1 supplying power to the load. The Source 1 Available and
Source 1 Connected indicators are lit. The sequence ends with Source 2 (generator) assuming
the load.
1. When Source 1 goes “out of spec," the control starts a Time Delay to Engine Start (TDES)
timer and the Source 1 Available indicator goes out.
2. If the TDES expires without a return to acceptable Source 1 power, the genset receives a
remote start signal. The engine starts and accelerates to rated speed.
3. When the alternator output reaches the “pickup" level, the Source 2 Available indicator is
lit. The control starts the Time Delay Normal to Emergency (TDNE) timer.
3.4.3.2.2 Transfer from Source 2 to Source 1 (OT)
This sequence begins with Source 2 supplying power to the load. The Source 2 Available and
Source 2 Connected indicators are lit. The sequence ends with Source 1 (utility) assuming the
load.
1. When Source 1 returns to “in spec," the Source 1 Available indicator is lit and the control
starts the Time Delay Emergency to Normal (TDEN) timer. When this time is complete, the
controller starts monitoring both live sources looking for when they are in sync
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