Onan RST 60, RST 100, RST 200 Installation Manual

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RST 60/100/200 Automatic Transfer Panel

Printed U.S.A. 913-0602B 9-2004

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PURPOSE

This supplement updates the LT, LC, and RST Operator’s, Installation, and Service Manuals to include information on the 5-button exercise clock available on current production units.

SUPPLEMENT USE

Write Refer to Supplement on the pages of the manuals listed above that refer to the exercise clock.

Insert this supplement inside the front cover of the manuals listed above.

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Page 2 of 8

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FIVE BUTTON EXERCISE CLOCKS

NOTE: After one minute of button inactivity, the

home menu (see Figure 2) will be redisplayed and any changes made that weren’t saved by pressing the OK button will be lost.

FIGURE 1. FIVE BUTTON EXERCISER CLOCK

Figure 3 shows the five operator buttons.

D The Menu button is used to activate a menu

or to break off the process.

D The Selector (Arrow) button is used to select

menu topics and one of the four available modes of operation (Automatic Operation Override Continuous Override Off

, Continuous Override On , and

, Manual

NOTE: The mode symbols are not included on the right side of the display (see Figure 2). They are included in this document for reference purposes only. The

button must point to the relative position of the symbol shown in this document to select the desired mode (see Figure 3).

D The OK button is used to save changes.

Figure 3 also shows the following clock features.

D The available menu topics are displayed at the

top of the screen.

D When being programmed, indicators for change-

over (SU/Wi) and the date (D/M/Y) are displayed beneath the menu topics.

D The clock displays the time and the day of the

week (1 = Monday).

D Around the clock are segments showing when an

exercise period is set.

D Near the right bottom corner is a circle indicating

the exercise state (black = active, white = inactive).

NOTE: There is an audible click whenever an exercise period starts or stops.

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D The and buttons are used to change val-

ues.

SUMMER/WINTER INDICATOR

REAL TIME, SWITCHING TIME

CLR = DELETE SWITCHING TIMES

COPY = COPY SWITCHING TIMES

FrEE = DAYS WHEN NO EXERCISE

PERIOD IS SET

ACTUAL DAY OF THE WEEK

OR PROGRAM DAY

SEGMENT DISPLAY OF THE

EXISTING PROGRAM

(1 SEGMENT = 30 MINUTES)

MENU BUTTON ACTIVATES

THE MENU OR BREAKS

OFF THE PROCESS

SELECTOR BUTTON

SU/Wi

MINUS AND PLUS BUTTONS CHANGE THE VALUES

MENU TOPICS

SET TIME CHECK... ON PROG DATE NEW...OFF

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D/M/Y

OKMENU

FIGURE 2. EXERCISER CLOCK HOME MENU

DAY/MONTH/YEAR

SYMBOL FOR AUTOMATIC OPERATION*

SYMBOL FOR MANUAL OVERRIDE*

SYMBOL FOR CONTINUOUS OVERRIDE ON*

SYMBOL FOR CONTINUOUS OVERRIDE OFF*

EXERCISE STATE:

ACTIVE INACTIVE

OK BUTTON CONFIRMS THE INPUT AND SAVES THE CHANGES

* THESE SYMBOLS ARE NOT

INCLUDED ON THE CLOCK.

FIGURE 3. FIVE BUTTON EXERCISER CLOCK FEATURES

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To reset the exerciser clock:

The clock is not pre-programmed. The clock can be reset to erase just the existing day and time settings or it can be reset to erase all existing day, time, and exercise program settings.

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D To erase just the existing day and time settings,

simultaneously press the MENU, +, and − but- tons. The screen will go blank. When the buttons are released two sets of dashes will be momentarily displayed (−− −−) and then the clock is displayed with the time set to midnight ( 0:00).

D To erase all existing day, time, and exercise pro-

gram settings, simultaneously press all five buttons. The screen will go blank. Release the MENU button while continuing to press the other buttons. Two sets of dashes will be displayed (−− −−). After three seconds have passed, release the remaining four buttons. The clock is then displayed with the time set to midnight ( 0:00).

To set the time:

1.. With the exerciser clock powered, press the

MENU button. Use the selector button

to se-

lect SET TIME which is displayed in the upper left-corner of the display (see Figure 4).

SET TIME

FIGURE 5. SET TIME

To set the date and summer/winter changeover:

1.. Press the MENU button. Use the selector but-

ton

to select SET TIME and press the OK

button.

2.. Press the selector button

to select DATE

and then press the OK button. The current year is displayed flashing and D/M/Y

is displayed

with the “Y” underlined (see Figure 6).

SET

DATE

D/M/Y

FIGURE 6. SETTING THE YEAR

3.. Press the + or − buttons until the correct year is displayed. Press the OK button. The day and month will then be displayed with the day flashing and D

/M/Y is displayed with the “D” under-

lined (see Figure 7).

FIGURE 4. SETTING THE TIME

2.. Press the OK button. The word “DATE” is dis- played. Press the OK button again. The time is displayed with the hour value flashing. The time displayed is based upon a 24 hour clock (military time).

Example: 2:00 PM = 14:00.

3.. Press the + or − buttons until the correct hour is displayed. Press the OK button. The minute value will then flash.

4.. Press the + or − buttons until the correct minute is displayed. Press the OK button. The home menu is redisplayed showing the set time (see Figure 5).

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SET

DATE

D/M/Y

FIGURE 7. SETTING THE DAY AND MONTH

4.. Press the + or − buttons until the correct day (1 thru 31) is displayed. Press the OK button. The month value will then flash and D/M

/Y will be

displayed with the “M” underlined.

5.. Press the + or − buttons until the correct month (1 thru 12) is displayed. Press the OK button. The summer/winter changeover menu is displayed with the selected region flashing (see Figure 8).

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SET

DATE

SU/Wi

FIGURE 8. SUMMER/WINTER CHANGEOVER

6.. To set the clock for summer/winter changeover

(daylight savings time), press the + or − buttons to select the appropriate region (see Table 1) and then press the OK button. The home menu is redisplayed. The matching number for the current day of the week will be underlined.

Examples: 1 = Monday

7 = Sunday

NOTE: If you do not wish any changeover, se-

lect the nonE setting. If you wish to set changeover times different from one of the preset times, select

and follow

the instructions included in Table 1.

TABLE 1. SUMMER/WINTER CHANGEOVER

INFORMATION

Choice

Euro Last Sunday in

Gb Last Sunday in

US First Sunday in

nonE No changeover No changeover —

Beginning of

Summertime

March

April

Freely programmable date with regards to the change from summer to winter time.

Northern Hemisphere:

Use the + and − buttons to put in the date at which the summer time starts and ends at your location/in your country. The weekday is automatically allocated to the date.

Southern Hemisphere:

For the southern hemisphere, the date at which the summer time starts/ends must be programmed for the same year.

Use the + and − buttons to set the year and then press the OK button.

Use the + and − buttons to set the actual day and month of summer time and then press the OK button.

Use the + and − buttons to set the actual day and month of real time and then press the OK button.

End of

Summertime

Last Sunday in October

Country/

Area

European Union

Great Britian

North America

To set exercise start and stop times:

NOTE: The start and stop time for an exercise peri-

od must both be in the same day. For example, you cannot have a 30 minute exercise period start at 23:45 on one day and stop at 0:15 on the following day.

1.. Press the MENU button. The selector button will pointing at PROG. Press the OK button.

2.. The selector button

will be pointing at PROG

NEW. Press the OK button again. “ON” is dis- played in the top right corner of the screen and the first day of the week is underlined (see Figure 9).

PROG NEW

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FIGURE 9. SETTING THE DAY OF THE WEEK THE

EXERCISE IS TO BEGIN

3.. To select a different day, press the + or − buttons until the desired day is underlined.

NOTE: If an exercise period is already set for

the selected day, the program and CL r will be displayed. If you wish to delete the set program, press the OK button.

4.. Press the OK button. The starting time (0:00) is flashed (see Figure 10).

PROG NEW

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FIGURE 10. EXERCISE CLOCK MENU

5.. Press the + or − buttons to set the starting time for the exercise (see Figure 11).

NOTE: If you lightly press the + or − buttons, the

value changes in one minute increments. If you press and hold the + or − buttons, the value changes in ten minute increments.

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PROG NEW

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FIGURE 11. SETTING THE EXERCISE STARTING

TIME

6.. Press the OK button. The starting time is still

displayed and “OFF” is now displayed in the upper right corner of the screen (see Figure 12). Press the + button to set the exercise stop time.

b. If you do not wish to set any additional exer-

cise periods, press the MENU button until the home menu is redisplayed.

NOTE: On the day that the exercise is to be-

come active, segments will be displayed around the clock showing when the exercise period is set (see Figure 14).

OFF

PROG NEW

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FIGURE 12. SETTING THE EXERCISE STOP TIME

7.. Press the OK button. Press the OK button again

to save the exercise program.

NOTE: If the Delete Program menu is dis-

played (see Figure 13), CL r is displayed, indicating that the exercise program can be deleted by pressing the OK button.

PROG NEW

FIGURE 13. DELETE PROGRAM MENU

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FIGURE 14. SET EXERCISE

To copy an exercise program:

1.. Once a set exercise program has been saved, press the selector button

to display the copy

menu (see Figure 15).

PROG NEW

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FIGURE 15. COPY EXERCISE MENU

2.. Press the + button to select the day of the week that you wish to include the same exercise period. Press the OK button.

8.. Copy the set program, set an additional exercise period, or exit the the program input.

a. If you wish to copy the set program, see “To

copy an exercise program” in the next column.

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3.. If you want the exercise to occur on additional days, repeat the copy procedure.

4.. To terminate setting exercise programs, press the MENU button until the home menu is redis- played.

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To erase (delete) exercise programs:

1.. Press the MENU button. The selector button will pointing at PROG. Press the OK button.

2.. The selector button

will be pointing at PROG

NEW. Press the OK button again.

4.. Repeatedly press the OK button to view the ex-

ercise starting and stop times. A clock is displayed showing the exercise start and stop times.

NOTE: If no exercise periods are set, FrEE is

displayed instead of the time.

3.. Use the + or − buttons to select the day of the week that the exercise is set. When the correct day is selected, segments will be displayed around the clock showing when the exercise period is set and Cl r is displayed in the center of the clock (see Figure 16).

4.. Press the OK button. The clock will be reset to midnight ( 0:00) and new exercise settings can be entered. If you do not wish to set up a new exercise period, press the MENU button until the home menu is redisplayed.

PROG NEW

FIGURE 16. DELETING THE EXERCISE PROGRAM

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TIME CHECK ON

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FIGURE 17. CHECKING THE EXERCISE START

TIME

5.. To terminate checking the exercise program,

press he MENU button until the home menu is redisplayed.

Permanent On/Off Mode:

The Permanent On/Off (Manual Override) mode reverses the set exercise state. It is initiated by using the selector button mode

(see Figure 18). The exercise state indica-

to select the Manual Override

tor shown in the bottom right corner of the display will then be reversed.

To check the exercise program:

1.. Press the MENU button. The selector button will pointing at PROG. Press the OK button.

2.. The selector button NEW. Press the selector button

will be pointing at PROG

button again

so that it points to TIME CHECK... Press the OK button.

3.. Use the + or − buttons to select the day of the week that the exercise is set to begin. Press the OK button.

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FIGURE 18. SELECTING PERMANENT ON/OFF

MODE

To exit the Permanent On/Off mode, press the selector button

until the Automatic Operation mode is selected. The exercise state indicator shown in the bottom right corner of the display will go back to its normal state.

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To initiate or override exercise program(s):

The exerciser clock has a built-in test feature. Once the clock time has been set, the selector button can be used to select Continuous Override ON mode Continuous Override OFF mode

to initiate a test (see Figure 19) or select

to cancel a test

in progress (see Figure 20).

To exit either mode, press the selector button until Automatic Operation mode

is selected. The exercise state indicator shown in the bottom right corner of the display will go back to its normal state.

Mains Failure:

If the clock is disconnected from AC power or the AC power source fails, “no U” is displayed (see Figure

21).

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FIGURE 19. CONTINUOUS OVERRIDE ON

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FIGURE 20. CONTINUOUS OVERRIDE OFF

FIGURE 21. AC POWER FAILURE INDICATION

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Table of Contents

SECTION TITLE PAGE

SAFETY PRECAUTIONS ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Panel Application 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Panel Protection 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Identification 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How To Obtain Service 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 MOUNTING 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wall Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outline Drawing − Cabinet Type 1 60/100 Amp 2-3. . . . . . . . . . . . . . . . . . .

Outline Drawing − Cabinet Type 1 200 Amp 2-4. . . . . . . . . . . . . . . . . . . . . .

3 WIRING 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Considerations 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AC Connections 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Connections 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection And Cleanup 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 SETUP AND CALIBRATION 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Before Calibrating 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Sensors 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Time Delays 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-Wire Start Module (Optional) 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exerciser Clock 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Float Battery Charger 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 SYSTEM CHECKOUT 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Test 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Transfer With Load 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Overcrank Function for Three-Wire Starting 5-2. . . . . . . . . . . . . . . . . . .

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.

WARNING

Page 11

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

WARNING

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 personal injury

or death.

CAUTION

This symbol refers to a hazard or unsafe practice that can result in personal injury or prod-

uct or property damage.

High voltage in transfer panel components presents serious shock hazards that can result in severe personal injury or death. Read and follow these suggestions.

Keep the transfer panel cabinet closed and locked. Make sure only authorized service personnel have access to the cabinet.

Due to the serious shock hazard from high voltages within the cabinet, all service and adjustments to the transfer panel must be performed only by an electrician or authorized service personnel.

Instructions to Authorized Service Personnel

If the cabinet must be opened for any reason:

1. Move the operation selector switch on the generator set to OFF. If the transfer panel is equipped with the 3-Wire Start Option, move the toggle switch to the Stop position.

2. Remove the AC power source to the cabinet.

3. Disconnect the starting batteries of the generator set (remove the ground [−] lead first).

Place rubber insulative mats on dry wood platforms over metal or concrete floors when working on any electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surfaces to be damp when handling any electrical equipment.

Jewelry is a good conductor of electricity and should be removed when working on the electrical equipment. 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.

Page 12

1. Introduction

INSTALLATION MANUAL

This manual provides information necessary for installing an RST (residential standby) transfer panel.

INTRODUCTION

The transfer panel is capable of automatic operation without operator involvement. It performs the following basic functions:

1. Senses interruption of the Normal power source.

2. Sends a start signal to the generator set (Emergency power source).

3. Transfers the load to the Emergency power source.

4. Senses the return of the Normal power source.

5. Retransfers the load to the Normal power source.

6. Sends a stop signal to the generator set.

NORMAL

OVERCURRENT

PROTECTIVE DEVICE

LOAD

OVERCURRENT

PROTECTIVE DEVICE

TRANSFER PANEL APPLICATION

Transfer panels are an essential part of a building’s standby or emergency power system. The Normal power source, commonly the utility line, is backed up by an Emergency power source, often an electric generating set. The transfer panel supplies the electrical load with power from either of these two sources.

The load is connected to the common of the transfer panel (Figure 2-1). 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 retransfer of the load are the two basic functions of a transfer panel.

RST Transfer Panel is a trademark of Onan Corporation.

EMERGENCY

FIGURE 2-1. LOAD TRANSFER PANEL

(TYPICAL FUNCTION)

TRANSFER PANEL PROTECTION

Transfer panels are continuously rated devices. With proper maintenance, they carry load currents up to their nameplate ratings for any time duration. Transfer panels are designed to withstand normally occurring surge currents from electrical devices in their load circuits. They are also designed to withstand the surge currents, which can occur on a short circuit or fault condition, as long as the available fault current does not exceed the rating of the panel and it’s protective device, and the transfer panel is installed with proper protective equipment.

Automatic transfer panels are required to be installed with appropriate overcurrent protection on

1-1

Page 13

the normal source side and the emergency side of the transfer panel (Figure 2-1). Protective devices may be circuit breakers, fuses, or other suitable overcurrent protective system components. A list of allowable protective equipment is affixed to the transfer panel. The listed protective device must be installed at some point in the circuit between the transfer panel and the electrical services that feed the device.

MODEL IDENTIFICATION

Identify your model by referring to the Model and Specification number as shown on the nameplate. Electrical characteristics are shown on the lower portion of the nameplate, which is located on the cabinet door.

When contacting the dealer or distributor regarding the transfer panel, always give the complete Model, Specification, and Serial number. This information is necessary to properly identify your unit among the many types manufactured.

HOW TO OBTAIN SERVICE

When the transfer panel requires servicing, contact your nearest dealer or distributor. Factory-trained Parts and Service representatives are ready to handle all your service needs.

If unable to locate a dealer or distributor, consult the Yellow Pages. Typically, our distributors are listed under:

GENERATORS-ELECTRIC, ENGINES-GASOLINE OR DIESEL, OR RECREATIONAL VEHICLES-EQUIPMENT, PARTS AND SERVICE.

For the name of your local Cummins



/Onan or Onan-only distributor in the United States or Canada, call 1-800-888-ONAN. (This automated service utilizes touch-tone phones only.) By entering your area code and the first three digits of your local telephone number, you will receive the name and telephone number of the distributor nearest you.

For the name of your local Cummins-only distributor, or if you need more assistance, please call:

Onan Corporation, 1-612-574-5000, 7:30 AM to 4:00 PM, Central Standard Time, Monday through Friday.

When contacting your distributor, always supply the complete Model Number and Serial Number as shown on the nameplate.

Cummins is a registered trademark of Cummins Engine Company. Onan is a registered trademark of Onan Corporation. PowerCommand is a trademark of Onan Corporation.

1-2

Page 14

2. Mounting

LOCATION

The location of the transfer panel varies with the application. Locate the panel in proximity of the commercial power supply circuit breaker. There should be enough room to add another circuit breaker to the emergency side of the transfer panel. A typical residential installation is shown in Figure 2-1.

The National Electrical Code (NFPA No. 70, Art 702−6) should be used as a guide for all AC wiring connections.

WARNING

installed by qualified electricians. Improper installation presents hazards of electrical shock and improper operation, resulting in severe personal injury or property damage.

There must be a service disconnect in the commercial supply power line ahead of the transfer panel.

Cabinet dimensions are listed in Table 2-1.

Choose a vibration-free mounting surface that will support the weight of the panel. Avoid locations where unauthorized persons can damage or open the cabinet or that are near flammable liquids or gases; such as fuel tanks, or are hot, moist, or dusty; such as dryer vent lines.

Electrical connections must be

WALL MOUNTING

1. Use four 3/8 inch bolts for wall mounting. Refer to Figures 2-2 and 2-3 for the outline drawing of the panel. Measure and mark wall for drilling. Before drilling, check the location to be sure that no wires, or plumbing, gas, or exhaust lines run behind the wall.

2. Install two mounting bolts in the wall for the top cabinet mounting keyholes.

3. With the shipping box standing so the cabinet is upright, carefully remove the top and sides of the shipping box.

4. Raise the cabinet and mount it on the two mounting bolts in the wall. Provide support for the cabinet during installation.

WARNING

vere personal injury. Have sufficient personnel for lifting and mounting the cabinet.

5. Install two bottom mounting bolts, but do not tighten. (Do not remove the cabinet support until all bolts are installed.)

6. Push the cabinet against the wall. If the cabinet will not align flush against the wall, shim the mounting bosses as required.

Improper lifting can cause se-

WARNING

Because an electrical arc will occur during transfer, the panel must not be located near batteries, fuel tanks, solvents, or other sources of flammable liquids or gases.

Amp

Rating

60, 120 lbs 29 in 18 in 11.06 in 28.43 in 100 (54.43kg) (737mm) (457mm) (281mm) (722mm) 200 155 lbs 34 in 21.5 in 11.06 in 31.87 in

7. Tighten all mounting bolts.

Refer to the outline drawings shown in Figures 2-2 and 2-3 for mounting hole dimensions.

TABLE 2-1. APPROXIMATE NEMA 1

CABINET DIMENSIONS

Depth With

Weight Height Width

(70.31kg) (864mm) (546mm) (281mm) (809mm)

Door

Closed Open

2-1

Page 15

UTILITY

ELECTRIC

SERVICE

GENSET

MAIN DISTRIBUTION PANEL

SUB-PANEL

TRANSFER

PANEL

ELECTRIC

DISCONNECT

GAS

LINE

ELECTRICAL SERVICE

FROM GENSET

NOTE:The transfer panel, sub-panel, and main distribution

panel must be installed inside the building

FIGURE 2-1. TYPICAL WALL-MOUNT INSTALLATION

2-2

Page 16

FIGURE 2-2 TYPICAL 60 & 100 AMP OUTLINE DRAWING

310-0924 REV. A

MODIFIED 6/99

2-3

Page 17

FIGURE 2-3. TYPICAL 200 AMP OUTLINE DRAWING

310-0925 REV. A

MODIFIED 6/99

2-4

Page 18

3. Wiring

WARNING

AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Only trained and experienced personnel are to perform the following procedures.

WIRING CONSIDERATIONS

The correct wiring hub must be used when installing conduit to maintain the cabinet rating. When installing conduit, observe the following precautions:

1. Before beginning conduit installation, cover the transfer panel to prevent accidental entry of metal chips.

2. If using rigid conduit between the generator set and the transfer panel, install at least 2 feet (610 mm) of flexible conduit between the rigid conduit and generator set to absorb vibration.

3. Run control circuit wiring in separate conduit from the AC wiring; otherwise, induced currents could cause operational problems within the panel.

Control wire must be of the stranded type. Do not use solid wire.

AC CONNECTIONS

Perform wiring in the following sequence:

1. Test the operation of the generator set from its own controls.

2. Stop the generator set by pushing the control switch to OFF and disconnect the negative (−) lead from the cranking battery to prevent starting.

WARNING

set from starting before wiring procedures are performed presents a shock hazard that can cause severe personal injury or death.

Table 4-1 shows the type and range of conductor sizes the transfer panel will accept.

TABLE 4-1. TERMINAL LUG CAPACITY

(FOR COPPER (CU) OR ALUMINUM (AL)

Panel Number of Size Range of

Amp Rating Conductors Conductors

60 1 2 - 10 AWG CU 100 1 2/0 - 14 AWG CU/AL 200 1 300 MCM − 6 AWG

GROUND LUG 1 4 - 14 AWG CU

Failure to prevent the generator

CONDUCTORS)

CU/AL

4. Cutouts can be made through the top, bottom, or sides of the cabinet. (Refer to the transfer panel control box outline drawings in section

2.)

CAUTION

Installation debris can cause equipment failure and damage. Use extreme care to keep drill chips and filings out of the relays, contacts, and other parts of the automatic transfer panel when mounting or connecting conduit. Screwdrivers should be used carefully to prevent damage to components.

3. Connect conductors of sufficient size to carry rated current from the line, load, and generator set directly to the transfer panel terminals.

The Normal power and Emergency power connections are marked L1, L2 and L3 The load connections are marked T1, T2 and T3. A neutral bar with lugs is standard. See Figure 3-1.

Use the National Electrical Code (NFPA No. 70, Ar t 702−6) as a guide for AC wiring connections and type between the genset and the transfer panel.

3-1

Page 19

NORMAL

POWER SOURCE

EMERGENCY

POWER SOURCE

A B C

L1 L2 L3

GND TERMINAL

FIGURE 3-1. RST GENSET LINE CONNECTIONS

4. On this 240-volt single phase switch, connect the two hot lines to the L1 and L3 lugs and connect the neutral line to the neutral bar.

5. Connect power cables to the load terminals T 1 and T3. Tighten the lugs as indicated in Table 4-2.

A B C

L1 L2 L3

NEUTRAL BAR

T1 T2 T3

A B C

LOAD

NOTE: 200 Amp panel is shown as reference only.

CONTROL CONNECTIONS

Connections of standard and optional control wiring are made at terminal blocks TB2 and (Figure 3-2).

optional

TB3

6. Make sure both AC power sources are disconnected.

WARNING

AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Make sure that both AC power sources are disconnected.

TABLE 4-2. LUG TORQUES

SET SCREW SOCKET SIZE MINIMUM TORQUE (ACROSS FLATS) FOR PROPER OPERATION

3/16 IN 80 IN-LBS (9 NM)

1/4 IN 200 IN-LBS (23 NM)

5/16 IN 275 IN-LBS (31 NM)

3/8 IN 375 IN-LBS (43 NM) 1/2 IN 500 IN-LBS (57 NM)

9/16 IN 600 IN-LBS (68 NM)

3-2

TB2

TB3 (OPTIONAL)

FIGURE 3-2. CONTROL WIRING CONNECTIONS

Page 20

Remote Start-Stop Connections

Use number 18 to number 12 AWG wire. Resistance must not exceed 0.5 ohm per line. Use stranded wire only. For connections to the TB2 screw terminals, use number 8 ring or spade terminals. For connections to TB3, strip the insulation back 3/8 inch (10 mm).

Two-Wire Starting:

ter-cooled generator sets uses terminals B+, GND (ground), and RMT of terminal block TB2.

Two-wire starting for Onan wa-

tached to TB2) is installed from TB2-2 to TB2-B+ and another from TB2-B+ to TB3-1. Make no other connections to TB2; terminals GND, 2, B+, and RMT.

WARNING

Improper wiring of start-stop connections can result in severe personal injury or equipment damage. Carefully follow all wiring instructions and make no other connections to TB2; terminals GND, 2, B+, and RMT when a three-wire start system is used.

(OPTIONAL) Three-Wire Starting:

(Available only

with a field installed 3-Wire Start Kit.) Three-wire starting for Onan generator sets uses

terminals 1, 2 , 3 , 4 , and 5 of terminal block TB3 (Figure 3-4).

Connect terminals 1, 2, 3, and 4 to terminals on the generator set, as shown in Figure 3-4. With diesel sets that use the preheat circuit, connect terminal 5 on TB3 to terminal H on the generator set control.

Terminals 6, 7 , and 8 of TB3 (Figure 3-5) are for connection to the overcrank alarm contacts. These (Form C) contacts are rated for 4 amperes at 120 VAC or 3 amperes at 30 VDC and are provided for customer use.

Ground Switching:

Determine whether your generator set has a switching ground or a switching B+ remote start system:

1. Measure the DC voltage from the Start terminal to the Ground terminal. (The starting battery must be connected.)

If 12 VDC is measured, it is a switching ground system.

If 0 VDC is measured, it is a switching B+ system.

For 3-wire start systems using a switching ground, install or make sure a jumper (provided in envelope attached to TB2) is connected from TB2-GND to TB2-2. Make no other connections to TB2; terminals GND, 2, B+, and RMT.

For 3-wire start systems using switching B+, install or make sure a jumper (provided in envelope at-

INSTALL JUMPER

TB2-1 TO TB2−2

FOR REMOTE

GROUND SIGNAL

INSTALL JUMPER

TB2-2 TO TB2-3 FOR

B+ REMOTE START

SIGNAL

TB2

GRD 2 B+ RMT 5 6 7 8

FIGURE 3-3. TWO WIRE START CONNECTIONS

GENERATOR SET

TERMINALS

BATTERY+

GROUND

STOP

START

PREHEAT

COM

OVERCRANK

ALARM CONTACTS

TB3

FIGURE 3-4. THREE-WIRE START CONNECTIONS

3-3

Page 21

INSPECTION AND CLEANUP

Inspect all wiring to be certain that:

• Wiring does not interfere with switch operation.

• Wiring will not be damaged as door opens and

closes.

• No wiring is left loose and unconnected.

After mounting and wiring the cabinet, clean the interior with a vacuum cleaner to remove any chips, filings, or dirt from the cabinet interior and components.

Installation is not yet complete. Do not energize the transfer panel until instructed to

do so in Sections 4 and 5.

3-4

Page 22

4. Setup and Calibration

BEFORE CALIBRATING

The RST transfer panel is equipped with two control package options:

• Control package A has preset undervoltage sensing and time delays.

• Control package B has adjustable undervoltage sensing and adjustable time delays.

After installing the transfer panel, the undervoltage sensing must be calibrated. Control package B and any optional electronic modules must be adjusted to the desired settings.

LOAD/NO-LOAD SWITCH

LOCATED ON CIRCUIT BOARD

EXERCISER CLOCK

LOCATED BEHIND COVER (CONTROL PACKAGE B ONLY)

CONTROL

BOARD COVER

LOCATED ON CIRCUIT BOARD

Install J1 Connector

Install connector J1 when all of the wiring is complete. Also install connectors for any installed options.

WARNING

rear side of the cabinet door present a shock hazard that can cause severe personal injury or death. Use extreme caution to avoid touching electrical contactors whenever the cabinet door is open.

AUTO/MANUAL SWITCH

CONTROL STATUS INDICATOR LEDS

LOCATED ON CIRCUIT BOARD

J1/P1 CONNECTOR

AC power within the cabinet and the

3-PHASE/1−PHASE

SWITCH LOCATED

BEHIND COVER

(CONTROL

PACKAGE B ONLY)

OPTIONAL

EXERCISER

CLOCK

(CONTROL

PACKAGE A)

OPTIONAL

3-WIRE START

BATTERY

CHARGER

GROUNDING LUGS

TB2

CONTACTOR

ASSEMBLY

NEUTRAL

BAR

FIGURE 4-1. LOCATION OF CONTROL COMPONENTS

4-1

Page 23

Connect the Battery

Make sure that the RUN switch on the generator is in the OFF position and connect the battery (negative [−] lead last). If applicable, reconnect the external battery charger.

WARNING

Ignition of explosive battery gases can cause severe personal injury. Do not smoke or cause any arc, spark, or flame while servicing batteries.

Connect AC Line Power

Connect AC line power to the automatic transfer panel. The Normal Available and Normal Connected LEDs on the control board will light if the voltage sensors are calibrated. See Figure 4-2.

VOLTAGE SENSORS

Control package A has undervoltage sensing for one phase of the Normal and Emergency sides with fixed pickup and dropout settings. The Pickup voltage is preset to 85% of Normal, and Dropout is preset to 75% of Pickup.

Control package B has three phase undervoltage sensing for the Normal side and single phase sensing of the Emergency side. This control has adjustable pickup and dropout settings. Pickup is adjustable from 85% to 100% of Normal, and Dropout is adjustable from 75% to 98% of Pickup. The adjustment procedure is described in the following section.

FIGURE 4-2. CONTROL BOARD LEDs

NORMAL

PICKUP

EMERGENCY

CALIBRATION

NORMAL

CALIBRATION

NORMAL

DROPOUT

EMERGENCY

PICKUP

EMERGENCY

DROPOUT

STOP

RETRANSFER

DELAY

TRANSFER

DELAY

START

FIGURE 4-3. CONTROL PACKAGE B ADJUSTMENTS

4-2

Page 24

Undervoltage Sensor Calibration

Voltage sensors monitor the Normal and Emergency power sources for an undervoltage condition.

• The Emergency sensor monitors the Emer-

gency (generator set) power source.

To calibrate the undervoltage sensors:

CAUTION

Incorrect setting of the calibration (Cal) adjustments will result in abnormal operation of the transfer switch.

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. Use extreme caution to avoid touching electrical contacts whenever the cabinet door is open.

All adjustments are made by turning the appropriate potentiometer with a screwdriver. The adjustment potentiometers are accessed by removing the cover from the control board.

A separate voltage sensor is used for each power source. The adjustment pot locations are shown in Figure 4-4.

• The Normal sensor monitors the Normal (util-

ity) power source.

Control Package A

1. Check that nominal voltage is present on all phases of the source being calibrated (Normal and Emergency).

2. Move the calibration switch (Figure 4-4) to the CAL position. Turn the Normal or Emergency calibration potentiometer fully counterclockwise.

3. Slowly turn the Normal or Emergency calibration (Cal) potentiometer counterclockwise until the Source Available LED corresponding to the source sensor being calibrated turns ON.

4. The undervoltage sensor is now calibrated. Repeat this procedure for the other source.

5. Move the calibration switch to the 85% position. This sets the sensor to 85% pickup and 75% dropout.

UNDERVOLTAGE

PICKUP AND

DROPOUT

ADJUSTMENT POTS

(4) CONTROL

PACKAGE B ONLY

FIGURE 4-4. UNDERVOLTAGE CALIBRATION, PICKUP AND DROPOUT ADJUSTMENT

CALIBRATION

SWITCH (S4)

CONTROL

PACKAGE A ONLY

POTENTIOMETERS

4-3

Page 25

Control Package B

1. Check that nominal volatage is present on all phases of the source being calibrated (Normal and Emergency).

2. Perform the following for the Normal source undervoltage sensor:

a. Turn the Normal Pickup pot (Figure 4-4)

fully clockwise to 100% pickup.

b. Turn the Normal calibration (Cal) pot fully

counterclockwise.

c. Turn the Normal Dropout pot fully clock-

wise to 97% dropout.

3. Turn on Normal source and check for nominal voltage.

4. Slowly turn the Normal calibration (Cal) potentiometer clockwise until the Normal Available lamp just turns ON.

5. Perform the following for the Emergency source undervoltage sensor:

a. Turn the Emergency Pickup pot fully clock-

wise to 100% pickup.

b. Turn the Emergency calibration (Cal) pot

fully counterclockwise.

c. Turn the Emergency Dropout pot fully

clockwise to 97% dropout.

6. Turn on Emergency source and check for nominal voltage.

7 Slowly turn the Emergency calibration (Cal) po-

tentiometer clockwise until the Emergency Available lamp just turns ON.

8. Turn off both power sources.

Proceed to Undervoltage Pickup and Dropout Adjustments.

Undervoltage Pickup and Dropout Adjustments (Control Package B Only)

Undervoltage dropout occurs when an undervoltage condition is sensed. Pickup occurs when an acceptable voltage is sensed. Undervoltage dropout and pickup are preset on control package A. Undervoltage dropout and pickup are adjustable over the following ranges on control package B:

FUNCTION ADJUSTMENT RANGE

Pickup 85% to 100% of nominal voltage Dropout 75% to 98% of pickup voltage

To set the pickup and dropout percentages, align the slots on the potentiometers with the desired markings as shown in Figure 4-4).

4-4

Page 26

TIME DELAYS

The time delays control the four following functions:

• Start time delay

• Stop time delay

• Transfer time delay

• Retransfer time delay

The time delays on control package A are preset as follows:

DELAY SETTING

Start 3 seconds Stop 5 minutes Transfer 3 seconds Retransfer 5 minutes

The time delays on control package B are adjustable over the following ranges:

DELAY ADJUSTMENT RANGE

Start 0 to 15 seconds Stop 0 to 10 minutes Transfer 0 to 120 seconds Retransfer 0 to 30 minutes

To set the time delays, align the slots on the potentiometers with the desired markings (see Figure 4-5).

FIGURE 4-5. CONTROL PACKAGE B TIME DELAY ADJUSTMENT

4-5

Page 27

3-WIRE START MODULE (OPTIONAL)

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 a preheat delay is desired, make sure that the Preheat timer’s On/Off switch is in the On position.

Programming the exerciser clock requires setting the time of day and entering the exercise start and stop times as described in the following sections. The exerciser clock has backup power for approximately six hours. After six hours the day and time will have to be reset. Exercise programs will not be lost during a power outage (exercise programs are stored in EEPROM).

To reset the exerciser clock program:

The Overcrank timer limits the time that the generator 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 potentiometers with the desired markings on the faceplate (Figure 4-6).

Resetting the exerciser clock erases all existing day, time and exercise program settings.

Depress and hold the arrow, plus and set buttons () (+) (

) 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 exerciser clock powered, press all three buttons simultaneously to reset the time. The time display area will show (− − : − −) and a small clock symbol will appear in the upper leftcorner of the display. Refer to Figure 4-7.

2. Press the arrow () button once to set the dayof-week. The clock symbol will begin flashing to indicate the clock is being programmed and the display will show midnight ( 0:00).

CLOCK

SYMBOL

PR INDICATES

PROGRAMMING

MODE

FIGURE 4-6. 3-WIRE START

EXERCISER CLOCK

The exercise clock is optional on RST Transfer Panels with control package A and is standard equipment on RST T ransfer Panels with control package B.

The exerciser clock is used to start and run the generator set at programmable intervals and for selected durations. It 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 exerciser clock also has a test feature that can be used to initiate a genset start and run cycle.

4-6

TIME

DISPLAY

DAY

DISPLAY

ARROW

FIGURE 4-7. EXERCISER CLOCK

PLUS

SET

Page 28

3. Press the plus (+) button as many times as necessary until the current day-of-week is displayed.

Example: 1 = Monday, 2 = Tuesday, etc.

4. Press the arrow () button again to set the hour of the day. The clock uses 24-hour (military) 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 minutes are displayed. Note that by holding the plus (+) button down, the minutes will increment in 5 minute intervals.

8. To set or change the exercise 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).

To set the exercise start and stop time:

1. Press the arrow () button four times to start the programming mode.

2. 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 programmed.

reached, press the set ( indicated, Figure 4-8).

Then increment the time with the plus (+) button to the desired Stop time. When the Stop time is reached, press the set ( Mode is indicated, Figure 4-8).

) button (ON Mode is

) button (OFF

Example to exercise the genset one hour: Set Start at 7:00 PM (19:00) Set Stop at 8:00 PM (20:00)

Note that the exercise time is indicated by a band of segments illuminated around the outer ring of the clock from the start to the stop time.

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 is 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 (+) (

Double check the program setting for each day . Press the arrow () button repeatedly until the clock mode is passed and the program mode (Pr) is reached. Carefully check each days program and clear any unwanted programs.

5. When finished programming, press the arrow () button until the clock appears in the upper left corner of the display.

During the exercise period, the ON mode is indicated in the ellipse in the upper right corner of the display (Figure 4-8).

) buttons at the same time.

To check the programs:

To clear an existing program for the day selected, press the plus and set (+) (

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 increment in 15 minute intervals. When the Start time is

) buttons at

Push the arrow () button to review each setting.

To erase (clear) a program:

Press the arrow () button until the program 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 (+) ( at the same time.

4-7

) buttons

Page 29

SEGMENTS INDICATE

EXERCISE TIME

TEMPORARY OVERRIDE MODE

(FLASHING HANDS INDICATES

PERMANENT ON/OFF MODE)

OFF MODE

ON MODE

To Initiate or Override an Exercise Program:

The exerciser clock has a built-in test feature. Once the clock time has been set, the set button (

) can be used to initiate a test or to cancel a test in progress.

With the normal source connected and available, pressing the set (

) button once initiates a test sequence. A hand is displayed in the upper left corner of the display and the ON mode is indicated inside the ellipse in upper right corner of the display (Fig-

ure 4-8). Pressing the set (

) button again stops

the test and the ellipse indicates the OFF mode.

To temporarily override an activated exercise program,

momentarily

press the set ( ) button. A small hand will appear in the upper left corner of the display (Figure 4-8). The current program is overridden and the clock automatically sets the next program. Momentarily pressing the set (

) button

again returns to the current program.

FIGURE 4-8. EXERCISER CLOCK ON/OFF MODE

Permanent On/Off Mode:

Holding the set ( ) button down until a

hand appears

in the upper left corner of the display

flashing

initiates the permanent On/Off mode. 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 (

) button momentarily toggles between the permanent On and permanent Off modes. Holding the set (

) button down until the clock symbol returns to the upper left corner of the display, ends the continuous On/Off mode and returns to the normal program mode.

4-8

Page 30

FLOAT BATTERY CHARGER

The float-charge battery charger 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.

CAUTION

Always disconnect the battery charger from its AC source (remove the charger’s AC input fuses) before disconnecting the battery cables. Otherwise, disconnecting the cables can result in voltage spikes high enough to damage DC control circuits.

NOTE: The pulsing meter indicates the charger is working.

The 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 J6/P6. The output of the battery charger is connected to the GND and B+ terminals of TB2 (or TB3 if the 3-Wire Start module is used). Refer to sheets 2 and 4 of the schematic and wiring diagram package.

Battery Charger Float Voltage

The float voltage is set at the correct value at the factory and should not require adjustment. However, 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.

WARNING

can cause severe personal injury. Do not smoke or cause any spark, arc, or flame while servicing batteries.

To check and adjust the float voltage, the following tools are needed:

Ignition of explosive battery gases

1. Turn the operation selector switch for the generator set to OFF 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 threewire start systems.

2. 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).

3. Connect the voltmeter directly to the battery terminals and measure the voltage.

Make sure the 12/24 volt selector switch is in the correct position.

4. Compare the voltage reading with the value shown in Table 5-1. 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.

• a fully charged test battery

• a hydrometer

• a small screwdriver

• an accurate voltmeter (0.5% accuracy

Checking the voltage:

Use the following proce-

dures to check the float voltage.

CAUTION

Do not attempt to adjust or test the battery charger with a deeply discharged battery. Use a fresh, fully charged battery when adjusting or testing the charger.

TABLE 5-1. BATTERY FLOAT

VOLTAGES

Lead-Acid Batteries

Battery Voltage Float Voltage

12 13.3

Nickel-Cadmium Batteries

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.

4-9

Page 31

5. Use a small screwdriver to turn the adjustment potentiometer (located on charger panel) counterclockwise to decrease the float voltage and clockwise to increase the float voltage. Adjust in small steps and wait five minutes for the voltage to stabilize before making additional adjustments.

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. Avoid touching electrical contacts. Do not wear jewelry or loose clo t h i n g . S t and on a dry , non-conductive surface such as a rubber mat or wooden platform.

6. When adjustments are complete, close and lock the transfer panel cabinet door.

7. Disconnect the voltmeter from the battery terminals and disconnect the test battery (negative [−] lead first) from the generator set.

8. 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.

4-10

Page 32

5. System Checkout

WARNING

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 Operation and Installation manuals.

STARTING TEST

Two-Wire Starting

1. Move the selector switch on the engine control to RUN. The generator set should start and run.

2. Move the selector switch to OFF. The generator set should stop. Return the selector switch to Remote for automatic operation.

Three-Wire Starting (Optional)

2. Push the start button on the generator set control. The generator set should start and run.

3. Move the Stop/Auto/Handcrank switch from Handcrank to Stop. The generator set should stop.

4. Move the Stop/Auto/Handcrank switch to Auto. The generator set should not start.

TEST TRANSFER WITH LOAD

1. Move the Load/No-Load switch on the control circuit board to the Load position (Figure 4−1).

2. Keep the Auto/Man switch in the Auto position at all times to enable the automatic retransfer function.

3. Replace the cover over the circuit board and close the cabinet door.

WARNING

and the rear side of the cabinet door presents a shock hazard that can cause severe personal injury or death. Close the cabinet door.

AC power within the cabinet

1. Move the Stop/Auto/Handcrank switch on the 3-Wire Start module to Handcrank.

LOAD/NOLOAD SWITCH

FIGURE 4−1. CONTROL CIRCUIT BOARD

4. Notify occupants prior to removing utility power.

AUTO/MAN SWITCH

5-1

Page 33

5. Turn o ff any electronic devices, computers etc. prior to removing utility power.

TEST OVERCRANK FUNCTION

THREE-WIRE STARTING

If the standby power is supporting all circuits within the home, turn off any electronic appliances and reduce other loads until the total load does not exceed 80% of the generator’s kW rating.

6. Remove the AC utility power to the transfer panel.

If the transfer panel is wired to a secondary distribution panel, open the breaker(s) in the main distribution panel that supply utility power to the transfer panel.

7. After testing, return AC utility power.

8. Keep the transfer panel door securely closed at all times and make sure only qualified service personnel have access to the cabinet.

If the optional 3-Wire Start module is installed:

1. Disconnect the positive start lead from the start solenoid or starter.

2. Move the Stop/Auto/Handcrank switch on the 3-Wire Start module to Auto.

3. Turn On the remote test switch (if connected). The Lockout lamp on the 3-Wire Start module should light at the end of the crank period (0 to 120 seconds—per setting).

4. Turn off the remote test switch.

5. Move the Stop/Auto/Handcrank switch to Stop and push the Overcrank Reset button (the Lockout lamp should go out).

6. Reconnect the positive lead to the starter or start solenoid.

7. Move the Stop/Auto/Handcrank switch to Auto.

5-2

Page 34

Cummins Power Generation 1400 73rd Avenue N.E. Minneapolis, MN 55432 1-800-888-6626 763-574-5000 International Use Fax: 763-528-7229

Cummins is a registered trademark of Cummins Inc.