Cummins Onan OTPCA OTPCB OTPCC OTPCD Transfer Switch 40-1000 Amperes Service Repair Manual INSTANT

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OTPC Transfer Switch 40 to 1000 Amperes Printed in U.S.A. 962–0516A 10-2002 Service Manual

i Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS vi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Introduction 1-1 About This Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Switch Applications 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility-to-Genset Control Operation 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility-to-Utility Control Operation 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator-to-Generator Control 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preferred Source Selection 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delays 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prime Power (Plant to Plant) Operation 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Stand-By Operation 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Levels 1 and 2 1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Identification 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Obtain Service 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Component Description 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabinet 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Panel 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Security Key Switch Option 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Display 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bar Graph Meter Panel 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control System 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Circuit Modules 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmed Transition 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Times 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test With or Without Load 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmable Generator Exerciser 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-Wire Starting 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Test Transfer 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Real-Time Clock 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Imbalance Sensor 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Rotation Sensor 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loss of Single Phase Sensor 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator-to-Generator Control Mode 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility-to-Utility Control Mode 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH, SEVERE PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SER- VICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/ OR MECHANICAL SERVICE.

ii Table of Contents (Continued) SECTION TITLE PAGE Electronic Control Options 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Relays Option 2-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay Module Option 2-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charger Option 2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charger Alarm Contacts Option 2-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Current and Power Sensor Option 2-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Shed Option 2-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PowerCommand Network Interface Module Option 2-9 . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Switch Assembly 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Assemblies 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Actuator 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capacitor(s) 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Switches 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Contacts 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Disconnect Switch 2-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing and Replacing Electronic Control Components 2-10 . . . . . . . . . . . . . . . . . . . . 3 Operation 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Programs 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmed Transition 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Times 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Exercise 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test With or Without Load 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer/Re-Transfer Inhibits 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Real-Time Clock 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PowerCommand Time Delays 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start Time Delay (TDES-A, and TDES-B) 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stop Time Delay (TDEC-A, and TDEC-B) 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Time Delay (TDNE) 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Retransfer Time Delay (TDEN) 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Programmed Transition (TDPT) 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elevator Time Delay (TDEL) 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PowerCommand Sensors 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Under-Voltage Sensing 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Over-Voltage Sensing 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frequency Sensing 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Imbalance Sensor 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Phase Rotation Sensor 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loss of Single Phase Sensor 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Events 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Operation 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Operation 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Start Test 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . With-Load Standby System Test 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Planned Maintenance 3-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii Table of Contents (Continued) SECTION TITLE PAGE 4 Digital Display Menu System 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menus 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Menus 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Navigation 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu Navigation 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu Descriptions 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Source 1 and Source 2 Sub-Menus 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Sub-Menus 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Statistics Sub-Menus 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Events Sub-Menus 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Sub-Menus 4-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Menu Navigation and Description 4-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Setup Parameters 4-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor 1 & Sensor 2 Sub-Menus 4-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Delay Sub-Menus 4-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Sub-Menus 4-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exerciser Sub-Menus – Software Versions Prior to 1.5.190 4-16 . . . . . . . . . . . . . . . . . . . Exercise Sub-Menus – Starting with Software Version 1.5.190 4-18 . . . . . . . . . . . . . . . . Exercise Exceptions Sub-Menus 4-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode Sub-Menu 4-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clock Sub-Menus 4-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequencer Sub-Menus 4-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Sub-Menus 4-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Sub-Menus 4-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Active TD Sub-Menus 4-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . InPower Service Tool 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Network Applications and Customer Inputs 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Module 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control LED Indicators and Switch 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Indicators 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exerciser Enable/Disable Switch 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of Events 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer from Source 1 to Source 2 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer from Source 2 to Source 1 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Using Fault Codes 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Events 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Flash-Out 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Warnings 5-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iv Table of Contents (Continued) SECTION TITLE PAGE Fault Event definitions 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Checksum Error 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Controller Battery 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATS Fail to Close: Re-Transfer 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATS Fail to Close: Transfer 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charger Malfunction 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Battery Low 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Communications Error 5-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting With Symptoms 5-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Warnings 5-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transfer Switch Service 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Membrane Switch Test 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module Test 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module 1 6-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Module 2 6-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Board Replacement 6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Calibration 6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup with a Capture File 6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Without a Capture File 6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . After the Setup is Completed 6-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Assembly Removal/Replacement Procedure 6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnect AC Power 6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reconnecting AC Power (When Finished) 6-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Actuator Removal and Replacement (40 to 125 Amperes) 6-9 . . . . . . . . . . . . . . . Removing Actuator 6-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Actuator 6-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Block and Cross-Bar Assembly Removal and Replacement (40 to 125 Amperes) 6-11 Removing the Block and Cross-Bar Assembly (Normal or Emergency) 6-11 . . . . . . . Replacing the Block and Cross-Bar Assembly 6-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Switch Removal and Replacement (40 to 125 Amperes) 6-15 . . . . . . . . . . . . . Removing Auxiliary Switch Assembly 6-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Auxiliary Switch Assembly 6-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Actuator Removal and Replacement (150 to 260 Amperes) 6-17 . . . . . . . . . . . . Removing Actuator 6-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Actuator 6-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Block and Cross-Bar Assembly Removal and Replacement (150 to 260 Amperes) 6-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Block and Cross-Bar Assembly (Normal or Emergency) 6-20 . . . . . . Replacing Block and Cross-Bar Assembly 6-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary Switch Removal and Replacement (150 to 260 Amperes) 6-24 . . . . . . . . . . . . Removing Auxiliary Switch Assembly 6-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Auxiliary Switch Assembly 6-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Actuator Removal and Replacement (300 to 600 Amperes) 6-26 . . . . . . . . . . . . Removing Actuator 6-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Actuator 6-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

v Table of Contents (Continued) SECTION TITLE PAGE Block and Cross-Bar Assembly Removal and Replacement (300 to 600 Amperes) 6-29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Block and Cross-bar Assembly (Normal or Emergency) 6-29 . . . . . . Replacing the Block and Cross-bar Assembly (Normal or Emergency) 6-32 . . . . . . Auxiliary Switch Removal and Replacement (300 to 600 Amperes) 6-33 . . . . . . . . . . . . Removing Auxiliary Switch Assembly 6-33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Auxiliary Switch Assembly 6-34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Linear Actuator Removal and Replacement (800 and 1000 Amperes) 6-35 . . . . . . . . . Removing Actuator 6-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Actuator 6-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Block and Cross-Bar Assembly Removal and Replacement (800 and 1000 Amperes) 6-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the Block and Cross-bar Assembly (Normal or Emergency) 6-38 . . . . . . Replacing the Block and Cross-bar Assembly (Normal or Emergency) 6-42 . . . . . . Auxiliary Switch Removal and Replacement (800 and 1000 Amperes) 6-43 . . . . . . . . . Removing Auxiliary Switch Assembly 6-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Auxiliary Switch Assembly 6-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mis-Wired Current Transformers 6-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Schematics 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vi OTPC-1 Safety Precautions This manual includes the following symbols to indi- cate potentially dangerous conditions. Read the manual carefully and know when these conditions exist. Then take the necessary steps to protect 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. ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH High voltage in transfer switch components pres- ents serious shock hazards that can result in severe personal injury or death. Read and follow these suggestions. Keep the transfer switch cabinet closed and locked. Make sure only authorized personnel have the cabinet and operational keys. Due to the serious shock hazard from high voltages within the cabinet, all service and adjustments to the transfer switch must be performed only by an electrician or authorized service representative. UTILITY-TO-GENSET OR GENSET-TO-GENSET APPLICATIONS If the cabinet must be opened for any reason: 1. Move the operation selector switch on the generator set to Stop. 2. Disconnect the battery charger. 3. Disconnect the starting batteries of the generator set or sets (remove the ground [–] lead first). 4. Remove AC power to the automatic transfer switch. If the instructions require otherwise, use extreme caution due to the danger of shock hazard. UTILITY-TO-UTILITY APPLICATIONS If the cabinet must be opened for any reason, remove AC power to the automatic transfer switch. If the instructions require otherwise, use extreme caution due to the danger of shock hazard. GENERAL PRECAUTIONS 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. Wear safety glasses whenever servicing the transfer switch and and do not smoke near the batteries. Do not work on this equipment when mentally or physically fatigued, or after consuming alcohol or any drug that makes the operation of equipment unsafe. WARNING INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH, SEVERE PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SER- VICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/ OR MECHANICAL SERVICE.

1-1 1. Introduction ABOUT THIS MANUAL This manual contains service procedures for an OTPC automatic transfer switch (ATS). This is an open transition (OT) transfer switch with Power- Command Control (PC). With an open transition switch there is never a time when both sources are supplying power to the load. Refer to the schematic and wiring diagram package that was shipped with the ATS for specific informa- tion about its configuration. Use normal and necessary safety precautions before starting any service procedure. Identify all hazards by referring to the Safety Precautions and ob- serve all warnings and cautions within the manual. Whenever you are troubleshooting, remember that the generator set, ATS, and utility power source are all interdependent. TRANSFER SWITCH APPLICATIONS Transfer switches are an essential part of a build- ing’s standby or emergency power system. Power Source 1 (Normal), commonly the utility line, is backed up by Power Source 2 (Emergency), often a generator set. The transfer switch automatically switches the electrical load from one source to the other. The load is connected to the common of the ATS (Figure 1-1). Under normal conditions, the load is supplied with power from Source 1 (as illustrated). If Source 1 is interrupted, the load is transferred to Source 2. When Source 1 returns, the load is re- transferred to Source 1. The transfer and retransfer of the load are the two most basic functions of a ATS. PowerCommand is a registered trademark of Onan Corporation. LOAD NORMAL EMERGENCY OVERCURRENT PROTECTIVE DEVICE OVERCURRENT PROTECTIVE DEVICE FIGURE 1-1. LOAD TRANSFER SWITCH (TYPICAL FUNCTION) UTILITY-TO-GENSET CONTROL OPERATION In utility-to-genset applications, the transfer switch performs the following functions: 1. Sense the interruption of the Source 1 power. 2. Send a start signal to the generator set (Source 2). 3. Transfer the load to the Source 2. 4. Sense the return of Source 1. 5. Retransfer the load to Source 1. 6. Send a stop signal to the generator set.

1-2 UTILITY-TO-UTILITY CONTROL OPERATION In utility-to-utility applications, the transfer switch performs the following functions: 1. Sense the interruption of the Source 1 power. 2. Transfer the load to the Source 2. 3. Sense the return of Source 1. 4. Retransfer the load to Source 1. Level 2 controllers can control a two-utility configuration for prime power. One utility is designated the preferred source. The control automatically transfers the load between the two utilities and detects alarm conditions. The exercise routine is not available in this configuration. The operator can select either source as the preferred source. See the Digital Display Menu System section. GENERATOR-TO-GENERATOR CONTROL The genset-to-genset control can be set up for two types of applications: • Prime Power – Two gensets provide all of the power (utility power is not available) • Dual Standby – Two gensets are used to back up utility power Note: The Test/Exercise function and Load Shed feature are not available in this configuration. If one genset fails to operate within the specified range of voltage and frequency, the transfer switch automatically starts and connects the other genset. Preferred Source Selection With both prime power and dual standby applications, either genset can be set up to be the preferred source. If the preferred source is changed while one of the gensets is running, the control starts the second genset and transfers the load to it, when it becomes available. Time Delays All the time delays are factory set and are adjust- able through the front panel display. The factory settings are: TDNE 10 SEC TDEN 600 SEC TDESa 3 SEC TDECa 600 SEC TDESb 3 SEC TDECb 600 SEC Note: TDESa and TDECa are for the Source 2 genset and TDESb and TDECb are for the Source 1 genset. Use the Time Delay sub-menus under Setup or the PC Service tool to change the settings. Prime Power (Plant to Plant) Operation In prime power applications, utility power is not available. The system includes one transfer switch and two gensets. One genset is always running and supplying power to the load while the other genset is the backup genset. An external power supply is not needed in this application. 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. 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 car- rying the load is always considered the preferred source. Automatic Changeover – The transfer switch can be set up to change the preferred source automatically by enabling the changeover timer. The Time Delay sub-menus under Setup or the PC Service tool can be used to enable the changeover timer and specify a changeover delay time period. 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 initi- ates a cool-down period (TDEC) on the old preferred genset before shutting it down. The old pre-

Cummins Onan OTPCA OTPCB OTPCC OTPCD Transfer Switch 40-1000 Amperes Service Repair Manual INSTANT

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