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(spec A-C) Transfer Switch Service Manual (08

1. 2 OPERA TON DESCRIP HON usd sesta ker ER 4 AT s with Control Accessory Groups 10 15 and 20 25 5 AT s with Control Accessory Groups 51 55 9 17 Changing Three Phase to 17 Changing Meter Lamp 1 18 Changing Control Accessory 19 Changing Control Accessory Panel AC System 21 Changing Contro Accessory Panel DC System Voltage 23 Two to Three Wire Start Conversion 12 25 Three to Two Wire Start Conversion 12 25 Adding Module to Control Accessory 26 ADJUSTMENT ss nha pa a Y ORC eee ee RUD SUCRE NU a dob bacc pa NN au ERU LIH 27 Latch and Latch Pin 27 COCE We 28 AC hoce SE cqni Me Teen 28 Undervoltage Sensor C
2. COVER w 507 104 EFIB 1 CLOCK PLANT EXERCISER I20V k sor O2 REPB ICLOCK PLANT EXERCISER 120v j 322 O9OKREFIA PLUG L NE DISCONMECT RI 3552 004GREFA RESISTOR OHM Z 5OHM 750 st SOS O32 REF P SWITCH TEST TRANSFER 82 wos oxeemerP 1 swircH SELECTOR 4 53 308 052 l SWITCH MANUAL AUTO s4 508 0175 1 ISWITCH RETRANSFER h 3 Ti 39 OM REFIB TRANSFORMER BATTERY CHARGER 344 0374 2 TRANSFORMER ASSY STEPCOWN Tel 332 1699 1 MARKER STRIP Tez 352 1616 A MARKER STRIP Tae 332 469 MARKER STRIP IHARNESS MA N 3 SHEETS 558 1 HARNESS MAIN 3 SHEETS 338 136 HARBESS RETRANSFER ss amp us4 D 1 HARNESS OVER V 3535 035 1 JHARNESS BAT V PLUB KETINO amp 352 2114 323 1054 P 12 QUIDES PC BOARD 307 157 P 2 SPRING RELAY HOLD DOWN 2 BRACKET FASTENER CONTROL ACCESSORY GROUP 15 a STANDARD 3 UNDER VOLTAGE SENSORSILINE LUNDER VOLTAGE SENSOR GEN 2 TO 3 WIRE CONVERTERIAT E ONLY NORMAL TEST SWITCH fi Ce M MANUAL PUSH TO RETRANSFER j
3. 10 With a stop watch or watch with second hand measure the time until the generator set starts cranking Insert a small screwdriver through START open ing in front panel of start stop time delay module 7 Turn START potentiometer clockwise to in crease start time delay or counterclockwise to decrease start time delay Make adjustments in small increments Move test transfer switch to NORMAL Measure time until generator set begins to shut down Turn STOP potentiometer with the small screw driver clockwise toincreasethe stop time delay or counterclockwise to decrease the stop time delay Make adjustments in small increments Repeat Steps 2 through 8 until desired delay times are obtained Move selector switch to desired position WITHOUT LOAD or WITH LOAD Close cabinet door Optional Start Stop Time Delay For setting the time delay ofthe programmable timer follow below procedure 1 2 3 Open right cabinet door of automatic transfer switch Pull out time delay module 7 from the control accessory panel Change the switch settings on the side of the printed circuit board for the desired times Figure 15 Table 1 lists the switch positions for the available time delays 300 1038 70 87 pn H vo Um FIGURE 15 START STOP TIME DELAY BEGIN SPEC Power Generation Example For a start time dela
4. 228 2218 23 amp RESET ASSY LEAD ASSY ex Gu Boror ds Hi RELATO 3 pp upon e Kis sorme 8 i RELAY TIME DELAY ON TRANSFER 300 SEG ON ENEAGIZATION sorsas a i MOUNTING PKG RELAY PNE sse zwo A 1 LEAO assy SCS 30720 1 CLOCK PLANT EXERCISER 608 307 105 1 JQLOGR PLANT EXERCISER 808417 PL 323 090 A 1 PLUG LINE DISCONNECT sor 376s 2 PLATE PANEL INTERLOCK sososol nse A 2 RESISTOR ASSY 500 A 2EW ISDHZ 24077 Ra 304 0131 i RESISTOR 750 25 6 i08m DoeS P 3WITCH TEST TRANSFER 52 308 0138 1 SWITCH SELECTOR Oo 2271 fetau caste qua KI 503 072 21 BUSHINQ RUBBER USE ON PI rBi 332 1699 1 MARKER STAP Z 332 469 1 marker srap 400 929 Hes ae O ESSE ey A 1 21 T 1 w 643 Y eames ze a 98 2795 0 1 SILKSCREEN PANEL FRONT TRANSFER e he o _ a 405 1872 nee Poe UNET 526 0003 2 WASHER FLAT 818 0150 2 RIVET DRIVE po SJE f tj WIRING HARNESS MAIN 301 2250 1 PLATE COVER O OR SWIN
5. 9 72 01 39y1304 174405 83804 20 135 351043919411610 OL 1407 ONY 0111504 351993015 01 2938150707 WO193HNQ 1531 QIMI 2542006 WOSM3S 38170A 43311 4 922174 34003304 1531 6810 6ES Redistribution or publication of this document by any means is strictly prohibited 1 Bl 99 Redistribution or publication of this document by any means is strictly prohibited 14034 40 ag buda 76 O 6 ES E 7252 3 qund mU wo una dun uini rite m m 0321755 AZ 778 Pd 55 20 2270727200 465340 diaz PP 7 5 swouswas nibsouuny sodpauuny ea y 031412345 ASIMAaHLO SSIINN 5324143101 NOIIV3Od3O NYNO 30 NOISIAIG Pag fond AYON P Twiaalyw NOlLdlu2s3Q Dona aoj wat vex zee 7 SWRIHHIL 2012 206 8 HOLOINNOD 1531 SILYA 5 Ji U OF AS 414405 83804 90 1198 44 9 A VC SLLVA A BES 38 TIVHS ZA 3 U OF MOA 9 rZ Aldd Y OL 1 HOLIMS 3501 2 3811514 1531 OLN ANDI A Zi OLAR 9014 i SILON 8 b6 0 6 Ed Power m Generation 7 A 539 095 Power vv BAT OR DC SUPPLY OR SOURCE USED FOR TEST RELAY 30791058
6. Oe PROCEDURE mep Redistribution or publication of this document by any means is strictly prohibited LORD USE VOLTMETER WITH HIGH DC RESISTANCE AND 172 9 ACCURACY MT VES YOLI POINT 304 A139 Lon LW 3158 9 96 EST CONNECTOR 2107 TERMINALS 327 2108 SCHEMATIC DIAGRAM TEST CIRCUIT TOPRRANCES OTHERWISE SPECIFI DECHAALS E a preprictes design mtermation an thy pet Quas repa s Caorparme na Comeppescs ansaded fy other Gre Power _ oF Generation Ca oa sent coronan a RA TEST PROCEDURE V fe on 446157195277 2116 4 19 33 AA 332 127 aal t je a r9 i ae WAS 332 1267 5 332 1 LA IW 5352 1269 TEST PROCEDURES PLUG FLOAT CHARGER INTO TEST CIRCUIT TURN CALIBRATE POT FULLY CLOCKWISE GHECK OUTPUT CURRENT APPLY 120V TO TRANSFORKER OBSERVE CHARGE CURRENT AND VOLTAGE CURRENT MUST EQUAL Of EXCEED 2 AMPERES AT t G YOLTS CLOSE LOAD SWITCH AND ADJUST AL TO INCREASE CURRENT VOLTAGE GOES ABOVE 12 0 WITH LESS THAN 2 AMPERES OUTPUT OPEN LOAD SWITCH CHARGE BATTERY UNTIL YOLTAGE RISES ABOVE 15 0 VOLTS SUBE REG COVERS 12 5 TO 13 9V RANGE FACTORY ADJUST TURN GALJ RATE PDT TO THE LEFT UNTIL THE CHARGE CURRENT DROPS TO
7. Ki SHOWN FOR REF ONLY KIT KI 526 0003 2 WASHER FLAT st omo RvET DRIVE LOAD 8 338 092 1 WIRING HARNESS MAIN 54 A PLATE COVER p L 301 4087 2 PLATE COVERIVOLT SENSOR 130i 4141 B8 1 PLATE COVER BAT CHARGER CONTROL ACCESSORY GROUP 5 5 INCLUDES ALL STANDARD ITEMS PLUS TD RETRANSFER 2 60 MIN EXERCISER CLOCK TD START 1 300 SEC TD TRANSFER 300 SEC TD STOP 2 6G0 MIN K TREM 571978 Taper 1502 0721 803 0278 18 TIT GjcHG LOCATION OF 51852 3 31 76 FIUPDATEDR5S R amp R SM x TE C fannen Jolson pae 01 6011 l2 40v DICHO NOTE 7 FOR 2 522 vj 2 5 x B GROUP NOWAS cos PONM 0 520 was 307 014 SY 7 7 0 nit K7 L3 an TA c TO ACTIVATE TRANSFER INHiBIT CIRCUIT REMOVE JUMPER CONNECT TO TB6 1I 2 OVERCRANK SIGNAL CONNECT TO TERMINAL 53 IN REMOTE ANNUNCIATOR TO ADD TD PREHEAT REMOVE JUMPER amp CONNECT TD PREHEAT TO TERMINALS H B8 ON TBI Qn DIVISIOH ATHAN AFTER TEST PLANT WILL RUN FOR DURATION OF TIME DELAYS ngn TO CONNECT RELAYS K7 AT E FOR 208V 60HZ WIRE K9 7 TO K7 L2 WIRE 4 1 TO
8. da amne ihe Qeon Don Omar Coperalien QCencbranen 4 Dc in to he 539 0188 Redistribution or publication of this document by any means is strictly prohibited Power Generation 2817 22 91 99 um a 6810 6865 HOSNSS A LYS 340939054 1541 mw ee eel Simeun jp upu Lnd MOLIYWO44O03 NYNO 20 NOISIAIG projie WWW emg aso n ON Lawa wii AL 02 5 f d Ez ANI WIE 68106 M x SUZ LEE 4012 8 ZEE ONE AS 4574 0750 7270 NO ALM TEN LV SAO FY LVNL ISN 539 0189 2 378 W d vA FINS LICA ZE E2 Mf 4 IIId WILIWLIM 277 GEESNEM EN NE RUN e ey JUI EROE C IEE SVM 8 SVM RL B2 5 o2W wg 2 V2 jro we wez amp E ae pepusiet pew QU alee Be pee lng 91H 41 324 V 81103 GS vin 8812665 2625006 IH 07 110 952 01 035119 51 SY 8 0 309 5110 c G2 OL 0343503 S 414405 dd Sv 5 911 SSO 05 39Y110A AU311Y8 801 135 9 17103885 0 0393807 N
9. 28D 29D 28D Three Phase Isolate malfunctioning voltage sensor by plugging each individual voltage sensor module into position 15 with bypass plugs in positions 13 and 14 Single Phase Replace voltage sensor module in position 13 290 Jumper TB4 9 to TB4 7 Does AT transfer load to normal line after retransfer time delay if any 30D 31D SOD Replace overvoltage line relay K6 31D Record the pick up voltage dial settings with small pencil marks on voltage sensor modules 1 2 and 3 only one in position 1 for single phase AT Turn pick up voltage knobs to 90 or below Does the AT retransfer the load to the normal line after retransfer time delay if any 32D 33D 32D Recheck the normal line voltage and output voltage of transformers T2 T4 and T5 for lower than normal readings Make sure voltage sensors are set for correct pick up voltages 33D Replace voltage sensor modules 1 2 and 3 with bypass modules or jumper TB1 GND to TB4 20 Does AT retransfer load to normal line after retransfer time delay if any 34D 35D 34D Three Phase Isolate malfunctioning voltage sensor by plugging each individual voltage sensor module into position 3 with bypass plugs in positions 1 and 2 Single Phase Replace voltage sensor module in position 1 35D Did relay K3 pick up to close contacts K3 6 9 and open K3 2 8 for control groups 10 15 or close contacts K3 3 5 and open
10. In order to check voltage sensor calibrations you must vary the input voltage to the respective transformer The following procedure isolates transformer T2 from the normal tine connection of the control and connects it to an independent power source Remove the transformer leads from T2 1 COM and 2 2 120 V from left side of the terminal strip and connect them to the output leads of a 120 volt variac 240 volt variac would require removal of transformer leads from T2 1 and T2 4 and connecting variac to these leads etc See Figure 14 Use instructions with Onan Multi Tester if used Note right side of terminal strip to see which terminal of T2 2 through T2 6 has an AC input lead for example a wire connected to T2 3 indicates 208 volts AC input On the left side of the terminal strip remove the corresponding T2 3 208 VOLT INPUT REMOVE LEAD 5 EN FIGURE 13 VOLTAGE SENSOR TRANSFORMER CONNECTIONS Power Generation 29 Redistribution or publication of this document by any means is strictly prohibited 14 15 16 17 18 19 20 120 VOLT SUPPLY transformer lead and tape it Figure 14 shows example of this If this transformer lead is already removed and connected to variac or Onan Multi Tester because its nominal voltage matches transformer input voltage ignore this step Connect a voltmeter to the output leads of th
11. STEPDOWN TRANSFORMERS T11 AND T12 ON METER LAMP PANEL FIGURE 1 Redistribution or publication of this document by any means is strictly prohibited 13 Close the meter lamp panel and secure the top 3 and bottom with two screws removed in Step 10 4 14 400 ampere AT only Close the left cabinet door and secure to inside center support with one screw removed in Step 6 15 Close the control accessory panel and reconnect the control panel disconnect plug 16 Restore AC line voltage to the AT 5 17 Reconnect the starting batteries 18 Move the operation selector to RMT on engine 6 controt for two wire starting or NORMAL in cabinet for three wire starting whichever applies 7 19 Close the cabinet door 8 CHANGING METER LAMP PANEL 9 To change a meter lamp panel in an automatic transfer switch use the following procedure 10 1 Open the front door of the cabinet 2 Move operation selector switch to STOP located in cabinet for three wire starting on 11 engine control for two wire starting s A _ 5 f SS ANC i3 A AS SS AK WA SS e 4 PZ ee lt y N 2 G M LI SN S VC e CU ae NS SS o T ZEE 4 Disconnect the starting battery Remove the AC line voltage from the automatic transfer switch Be sure to remove
12. Throughout the text front of the automatic transfer switch is the door side Determine left and right when facing the cabinet doors Metric equivalents of U S customary units will appear in parentheses where applicable 3 Starting Circuit C 2 wire 24 volt D 2 wire 12 volt E 3 wire 12 volt 4 Transfer Switch and Cabinet Combinations 5 Current Rating amperes 6 Voltage Code 3 120 240 1 3 wire 4 120 208 3 phase 4 wire 4X 277 480 3 phase 4 wire 5D 120 240 3 phase 4 wire delta 7 220 380 3 phase 4 wire 9X 347 600 3 phase 4 wire Voltage code with prefix 5 indicates 50 hertz e g 53 indicates 50 hertz 120 240 volts 1 3 wire continued on next Redistribution or publication of this document by any means is strictly prohibited Power _ zd Generation rp 7 Control Accessory Group GROUPS 10 THROUGH 15 AND 20 THROUGH 25 SOLID STATE MODULAR TYPE e i N gt ACCESSORY _ Standard Items _ Start Stop Time Delay i _Undervoltage Sensor 1 sensor on emergency side Transfer Retransfer Time Delay Battery Charger Module Battery Voltage Sensor Undervoltage Sensor 1 sensor phase normal side Overvoltage Sensor 1 sensor phase normal side Exerciser Clock Manual Retransfer Switch Preheat Time Delay AT E Only W Wo X Supplied standard Includes nor
13. USE LAMPS THAT ARK COMPATABLE WITH BATTERY 8lWAs 3ss2 4 267 A lt ADDED NOTE N9 G 2 8 D UPDATED TEST BOARD HOOK UP ___ 4 45 00016 21 76 ur NOTES PLUG 12 Y 0 START STOP 3000924 INTO TEST FIXTURE APPLY 1 10 15 YOC TURN BOTH START ANG STOP TO MINIMUM COUNTERCLOCKWISE POSITION MEASURE MINIMUM TIME DELAY 41 START CLOSE SWITCH 51 AND MEASURE TIME DELAY BETWEEN SWITCH CLOSURE AND RELAY PICKUP TINE MUST BE LESS THAN 0 5 SECOND 42 STOP OPEN SWITCH 51 AND MEASURE TIME DELAY BETWEEN THE SWITCH OPENING AND RELAY DROP OWT TIME MUST BE LESS THAN 0 5 MINUTES FACTORY SET TIME DELAY 9 1 START TURN START ADJ CLOCKWISE CLOSE SWITCH 51 AND MEASURE DELAY TIME MUST EXCEED 15 SECONDS ADJUST FOR 2 5 0 5 SECONDS DELAY 5 2 STOP TURN STOP ADJ CLOCKWISE OPEN SWITCH 51 ANO MEASURE DELAY TIME MUST EXCEED 5 MINUTES ADJUST FOR 5 50 5 MINUTES HOLDING CURRENT REDUCE VOLTAGE TO Ye RATING CRI4 SHALL STAY IN POSITION DIVISION ONAN CORPORATION Minnespells Minneseate TEST PROCEDURE 12 START STOP 539 0195 Redistribution or publication of this document by any means is strictly prohibited Generation ch m3 539 0196 BAT OR DC SUPPLY 4 START GRN STOP RED USE LAMPS THAT ARE COMPATABLE WITH RELAY 301 910550 300C977 5398195 p
14. _ _ CONNECT RELAY TD ON RETRANSFER 50 60 CABINET MI E 336 2309 A LEAD ASSY E IKIS 1307 1144 8 R LAY TIME DELAY ON TRANSFER 301 3315 MOUNTING PKG RELAY PHL 07 103 t CLOCK PLANT EXERCISER 80Hz 17307 1105 B t CLOCK PLANT EXERCISER 50 a Ei 323 090 t PLUG LINE DISCONNECT 38i 3765 a 2 PLATE PANEL INTERLOCK INFEALOCK 1503 0890 11 HOSE R3 355 0055 RESISTOR S CL IOW CONNECT TO R4 304 0155 f t AESISTOR 750N 25W O amp O REMOTE TERMINAL zl 5 R5 6 504 0718 2 RESISTOR ASSY 500 25W SOHZ 240N Isi 506 0069 t 5WITCH TEST TRANSFER BLOCK ON PLANT 82 308 0 93 A I SWITCH SELECTOR amp et A LPP Susi aaa ee en ae a ae FI ENMEC TIEREN MARKER STRIP ni 5 2 fa pr 9 10 929 E EE p R3 I tas 9 KY P 1 8 BEER USE ON 52 lt 1 iets S sls 3 so sses o 1 PANEL SWINGING RELAY K L2 93 27950 SILKSCREEN PANEL FRONT TRANSFER SW CONTACTS LOAD 58 2796 6 SIKSEREEN PANEL REAR 3e LINE amp GEN TERMINALS 405 872 2
15. MODIFICATIONS Modifications to the automatic transfer switches are described in this section At the end of the section instructions are also given for adding a module to the control accessory panel of groups 10 15 20 25 For calibration checks and adjustments of new modules or relays etc see the ADJUSTMENTS section Throughout any modification follow the in m structions carefully Otherwise the automatic transfer switch and generator set present a serious shock hazard CHANGING THREE PHASE AT TO SINGLE PHASE To change a three phase AT to a single phase AT use the following procedure 1 Open the cabinet door of the automatic transfer switch 2 Move the operation selector switch to STOP on the engine control for two wire starting in cabinet for three wire starting 3 Disconnect the battery cables of the starting batteries 4 Remove the AC line voltage from the automatic transfer switch Failure to remove AC power from the automatic transfer switch and to disable the generator set presents a serious shock hazard during this modification 5 Remove the control disconnect plug and open the control accessory panel 6 400 ampere AT only Remove one screw from the inside center support for the left cabinet door and open 7 Remove generator line and load connections from the transfer switch terminal C 8 Connect single phase generator line and load connections to respective t
16. NO LIBET OCC a REVISED RELAY MOVED FROME 2 3 JUMPER MOVED FROM 5 nd DEAS 27 73 19 27 7 3 04 6 5 79 3 0 6 5 79 WAS k 242A 19 G WAS 332 1271 WAS 332 1269 TEST PROCEDURE FOR VOLTAGE SENSOR 300 0780 SET DIFF DROPOUT CONTROL 57 THIS 15 115V POSITION 3 SET CALIBHATE CONTKOL TU FULL CLOGKaISE POSITION AITH A NARRUK BLADE SCREWDRIVER ENERGIZE TEST CIRCUIT ALJUST FOR 115 VOLTS INPUT fra Eid THE CALIBRATE CONTROL CCW UNTIL RELAY PICKS UP OR RELAY 5500 9 DAOP OUT AT APPROXIMATELY 103 VOLTS SET PICK UP CONTROL TO 90 VOLTS THEN SLOYLY INCREASE INPUT YOLTS SEE THAT RELAY PICKS 90 2 VOLTS RELAY SHOULO DROP RELAY MUST PILK UP AT 140 2 2 VOLTS DIAL MUST HAVE RANGE TO COVER 90 VOLTS TO 140 VOLTS F IT WILL NOT T WILL BE NECESSARY TO CHANGE CALIBhATE POINT SLIGHTLY DECREASE INPUT VOLTAGE SLOWLY RELAY 550010 DROP OUT APPROXI MATELY 153 4 VOLTS INCREASE VOLTAGE 140 VOLTS RELAY UDES NOT PICK UP ADJUST PICK UP CBNTROL UNTIL RELAY UDES DPERATE SET DIFF DROPOUT CONTROL 20 THEN REDUCE INPUT VOLTACE SHOULD 850P OUT 112 4 VOLTS ITEM PART NO QTY DESCRIPTION OR MATERIAL oo DIVISION GF STLDEBARES CORPORATION RELAY we Minasupols
17. 10 THIS CONTACT SYMBOLIZES 50110 STATE SWITCH THAT CLOSES WHEN VOLTAGE GOES ABOVE NORMAL AI3 AE4 415 THIS CONTACT SYMBOLIZES A SOLID STATE SWITCH THAT CLOSES AFTER A DELAY OF SEC TO 5 SEC DELAY ON LOAD TRANSFER 2 2 TO3WIRE CONVERTER E ONLY TRE SELECTOR SW HAS THREE POSITIONS 5 PLANT PREVENTS STARTING USE THIS POSITION FOR SERVICING PLANT NORMAL ALLOWS PL ANT START ASSUMES LOADIF A LINE FAILURE OCCURS HARD CRANK PREVEHTS AUTOMATIC START ALLOWS STARTING B STOPPING AT THE PLANT USE TH 5 POSITION FOR PLANT MAINTENANCE 15 THIS DASHED LINE REPRESENTS A JUMPER CIRCUIT THAT MUST BYPASS A CONTACT OR CLOSE A CIRCUIT TO OPERATE WITHOUT THE REFERENCED MODULE I4 THI5 CONTACT SYMBOLIZES SOLID STATE SWITCH WHICH CLOSES AFTER 5 TO 30 MIN DELAY ON RETRANSFER 15 WIRE TRANSFORMERS 2 5485 208V CONNECT 74 TO T2 3 T5 9 T4 3 15 9 T2 4 T3 10 15 10 2 5 T3 H 14 5 T5 1l T2 6 T3 12 T4 6 T5 l2 7 T5 7 T2 1 T4 1 TB6 7 T5 7 T2 1 T I TB6 7 T5 7 T2 1 14 1 786 7 T5 7 l i6 WIRING DIAGRAM SHOWS CIRCUIT AS IF ALL ADDER PACKAGES WERE INSTALLED PLUS IT SHOWS JUMPERS REQUIRED WHEN THEY ARE NOT INSTALLED 17 TO ADD PARALLELING SWITCH BOARD TRANSFER INHIBIT CIRCUIT REMOVE JUMPER TBI 687 IB OVERCRANK SIGNAL ON AT E ONLY CONNECT TO TERMINAL 53 N REMOTE ANNUNCIATOR FOR 240V COHNECT FOR 480V CONNECT
18. D MODULE FROM CONTROL ACCESSORY PANEL n 7 147 10 Close control accessory panel and connect dis connect plug Module extended from extension board module is now energized and presents a serious shock hazard Perform module adjustments or tests using ap propriate instructions 11 When the tests etc are completed remove twist lock disconnect plug and open control accessory panel 12 Remove both modules from the control accessory panel 13 Reinsert keying plug s removed in Step 6 into printed circuit board receptacle 14 Plug in module removed in Step 5 or install new module if required into control accessory panel 15 Close control accessory panel and connect dis connect plug 5 16 Move the operation selector switch to REMOTE two wire starting on engine control or NOR MAL three wire starting in cabinet whichever applies 17 Close cabinet door VOLTAG E SENSOR DROPOUT oat SPARE SPARE SPARE Pick up VOLTAGE C FIGURE 23 EXTENSION BOARD MODULE IN CONTROL ACCESSORY PANEL T Power Generation 33 Redistribution or publication of this document by any means is strictly prohibited Voltage Sensor and Transfer Retransfer Time Delay Bypass Plug Module Use a 300 1675 bypass plug module for begin Spec C automatic transfer switches a 300 0927 bypass module for Spec A and Spec B automatic t
19. T 1 PLUG IN MODULE PACKAGES 3 OVER VOLTAGE SENSORSILINE fe jan was NN EE 6 13 70 5 5 75 CLOSED CONTACTS AD tO PS rz TD TRANSFER RETRANSFER 120 was2o0v TD PREREAT 5 500 5720 UT WAS 4 1 98 76 BATTERY VOLTAGE SENSORS F 5 r13 0 9 301 4727 WAS 1405 TA amp DI THRU O06 ASizz S 2 14 As Mi WAS 301 5487 c asngo Rer To samaita 521 1 B REM RSE 9 was TO Cae DIVERON OF Sannom orr Per NM CONTROL ACGESS PANEL WIRING DIAGRAM EXERCISER CLOCK ares 208 240 480 600Y 13 4 W 50 amp 0 Hr Redistribution or publication of this document by any means is strictly prohibited 626 0075 e REF DES PART NO wau WIRING DIAGRAM REAR VIEW 36 INE sommosse 1 RELAY INTERPOSING LINE 240V E ps wetar wTeneosme Gen TRANSFER SW CABINET 7 RMT CSTR 1 PROTECTION 24071 kr soruse s i IaeLay Twe DELAY ON STARTING 500 SEC DE EMERGIZATION 39 355 1 MOUNTING PKG RELAY PNL soz orz4 s 1 RELAY TIME DELAY ON STOPPING Ss PI CY
20. The generator set continues to run until the start stop time delay drawing 626 0445 times out to de energize start relay K7 Contacts K7 4 7 open to remove B from the remote RMT line If the generator set is a 3 wire start 2 to 3 wire converter module 9 removes ground from TB1 terminal 3 and puts ground on TB1 terminal 2 to stop the generator set SIMULATION OF POWER OUTAGE To ensure that the equipment is ready to perform if an actual power outage occurs the operator should periodically simulate a power outage The Onan automatic transfer switch has two switches to provide a choice of testing or exercising the generator set with load or without load Without Load To test the generator set without load place selector switch 2 in the WITHOUT LOAD closed position drawing 626 0445 Then place the test transfer switch in the TEST position to complete the circuit from the battery positive terminal through S1 1 2 and 52 2 3 to the remote RMT line This signals the generator set to start and run unloaded as long asthe switch is in the TEST position To stop the generator set return the test switch to the NORMAL position Redistribution or publication of this document by any means is strictly prohibited o gee E Pal illii Generation E adi XP vu E With Load To tesi the generator set under actual operating conditions set selector switch S2 to the WITH LOAD Open positio
21. Si Emne DESCRIPTION MATERIAL __ JYM iie o n a Oe wie ar Te ele A Ons Minneapolis Minnesota TEST PROCEDURE 24 START STOP jwetd oa t wr do Va Te er f arse arsos arse p 539 0196 Redistribution or publication of this document by any means is strictly prohibited cr 539 0 99 51 DR 00 SUPPLY TRANSFER D 2 RETRANSFER Em 6 4 79 OCTAN ERARA WAS 332 1271 4 ALL Y NOTES 1 PLUG 12 V T D TRANSFER 3000024 TEST FIXTURE 2 APPLY 12 TO 15 VDC 3 TURN TRANSFER ADJ TD MINIMUM COUNTERCLOCKWISE POSITION 4 MEASURE MINIMUM TIME DELAY 4 1 TRANSFER CLOSE SWITCH 1 AND MEASURE TIME DELAY BETWEEN SWITCH CLOSURE AND RELAY Ki PICKUP MUST BE LESS THAN 0 5 SECOND 5 FACTORY SET TIME DELAY 9 1 TRANSFER TURN TRANSFER ADJ CLOCKWISE CLOSE SWITCH 51 AND MEASURE DELAY ADJUST FOR 2 5 0 5 SECONDS DELAY USE LAMPS THAT ARE COMPATABLE WITH BATTERY OR HUST EXCEED 15 SECONDS SOURCE USEO FOR TEST USE RELAY 30781058 FOR KI amp K2 USE DIODE 357A4 FOR CAI CR2 CA 2 TEST CONNECTOR Z57 527 392 2107 A 539 200 stem St DESCRIPTION OR MATERIAL Cue J MORK Piere e 1 DIVISION OF ONAN CORPORATION 332 2108 A TOLERANCES UNLE
22. WITH 13 3 VOLTS AT BATTERY TERMINALS FOR LEAD ACIO BATTERIES DR 14 0 VOLTS FOR NICKLE CADMIUM BATTERIES UNLESS ORDER SPECIFIES SOME DTHER VOLTAGE PUT A SPOT OF GLYTQL OR PAINT DN TRE SHAFT AND BONY TO SERVE AS A REFERENCE POINT miu FLO AT CH ARGER Redistribution or publication of this document by any means is strictly prohibited 539 0164 LORD Re USE VOUIMETER WITH 2 HIGH DC RESISTANCE AND 1 17 ACCURACY BY 15 YOU POINT 3159693 EST CONNECTOR 8 3 1 2107 TERMINALS 337 2108 A SCHEMATIC DIAGRAM TEST CIRCUM B IWAS 332 1271 4 24 WAS 332 1269 p TEST PROCEDURES PLUG FLOAT CHARGER INTO TEST CIRCUIT TURN FLOAT VOLTAGE ADJUSTMENT POT FULLY CLOCKWISE APPLY 120v TD TRANSFORMER OBSERVE CHARGE CURRENT AND VOLTAGE CURRENT MUST EQUAL OR EXCEED 2 AMPERES AT 25 2 VOLTS CLOSE LQAB SHITCH AND ADJUST RL TO INCREASE CURRENT IF VOLTAGE GDES ABOVE 25 2 WITH LESS THAN 2 AMPERES OUTPUT OPEN LOAD SWITCH CHARGE BATTERY UNTIL VOLTAGE RISES ABOVE 26 6 VOLTS TURN FLOAT VOLTAGE ADJUSTMENT POT THE LEFT UNTIL THE CHARGE CURRENT DROPS TO ZERO WITH 26 G VOLTS AT BATTERY TERMINALS PUT SPOT OF GLYTOL OR PAINT ON THE POT SHAFT AND BODY SERVE AS A REFERENCE POINT DESCRIPTION OR MATERIAL PART NO MERE 559 Biles gt pie s Ea e tr t Ri rm Ongn BrvisiOr assem PUNCH WELD
23. carefully engaging top hinge pin Center the hole on the bottom contro panel flange over the hinge pin Insert the screw in bottom hinge pin and tighten with screwdriver and pliers Install terminal boards TB1 and TB6 from new control accessory panel Connect loose wires in cabinet to terminal blocks as marked Power _ Generation Remove the external wires from TB6 21 15 16 17 18 19 20 21 If an area protection circuit or a remote test switch is used remove the jumper between terminals TB1 4 and 5 and connect the wire leads from the equipment Close the control accessory panel and reconnect the twist lock disconnect plug Set the time delays following instructions in the ADJUSTMENTS section Restore AC line voltage to the automatic transfer switch Heconnect the starting batteries Move the operation selector switch to RMT on engine control for two wire starting or NOR MAL in cabinet for three wire starting whichever applies Close cabinet door of automatic transfer switch CHANGING CONTROL ACCESSORY PANEL AC SYSTEM VOLTAGE This modification applies only to control accessory panels iri groups 10 15 and 20 25 If the control accessory panel has been changed and its nominal voltage differs from the automatic transfer Switch use the following procedure 1 2 Open automatic transfer switch cabinet door Move the operation selector switch to S
24. closed during exercise period See instructions for exercise clock adjustments 7G 16G 4 7G Jumper terminal K5 1 to K5 2 Does generator set start and run 8G 9G 8G Replace cranking limiter assembly 9G Does AT have a preheat time delay for a diesel generator set 10G 13G 10G Has preheat time delay completed its delay 11G 11G Does generator set start and run if terminal TB1 H is jumpered to TB1 3 12G 13G 12G Check preheat time delay for open and replace time delay if necessary 13G Jumper contacts K4 1 2 Does engine crank 14G 14G Replace relay K4 15G Repiace the exerciser clock 16G Replace the microswitch on the exerciser clock or replace exerciser clock 78 Redistribution or publication of this document Generation by any means is strictly prohibited 1H Has overcrank reset button popped out on control accessory panel 2H 2H Is battery voltage present between terminals TB6 1 and TB6 9 3H 4H 3H Check wire connections at overcrank lamp Replace lamp if burned out x 4H Check cranking limiter K5 and repiace if necessary 7 4 Power 19 Redistribution publication of this document 4 Generation by any means is strictly prohibited Redistribution or publication of this document by any means Is strictly prohibited Redistribution or publication of this
25. load to line when generator set is not operating NO Is normal line energized and delivering rated voltage to the line terminals of the transfer switch Is control panel disconnect plug properly inserted into receptacle is test transfer switch 51 in the NORMAL position Does automatic transfer switch have NORMAL and EMERGENCY indicating lamps Is the green NORMAL lamp lit 9A Are contacts K1 CS closed to connect rated voltage across closing coil Ki CC Repair or replace K1 CS contacts Is closing coil K1 CC open circuited or is there an obstruction preventing transfer switch from closing Does automatic transfer switch have area protection equipment or remote test switch connected to terminals TB1 4 and TB1 5 12A Jumper terminals TB1 4 and TB1 5 Does AT transfer load to line 12A Check area protection equipment or remote test switch for malfunction circuit must be closed for retransfer Is this a three phase AT 16A Jumper relay contacts K6 3 5 Does this correct problem 16A Clean contacts K6 3 5 Does this correct problem 15A Replace relay 6 isis Does AT have a retransfer time delay K10 20A Jumper relay contacts K4 5 6 Does this correct problem 20A Clean contacts K4 5 6 Does this correct problem 19A Replace relay K4 E Are relay contacts K3 5 6 contacts K3 3 4 for 480 and 600 volt system closed and making good contact 21A Clean contacts K3 5 6 K3 3 4 for 480 and 600 volt sy
26. moditication Remove the twist lock disconnect plug and open the control accessory panel whichever applies 6 Remove the wire lead from transformer T1 ter 21 th duor minal T1 X2 and connect to terminal T1 X3 ose caDine oor Figure 7 7 Remove the wire lead from resistor R1 terminal From 12 to 24 Volts R1 2 and connect to terminal R1 3 See Figure 8 TENE 8 Remove the 12 volt battery charger module 6 ome control accessory panels do not have all the items mentione the following procedures For example group 10 panel does number 300 0793 and replace with the 24 volt not have a battery charger module battery charger transformer T1 module number 300 0794 charger resistor R1 high and low battery voltage indicator lamps 9 Remove the 12 voit module 5 number 300 0847 0814 0813 item replace with the 24 to 12 volt converter moduie number 300 0848 1 Open the automatic transfer switch cabinet door 10 lela d the 12 volt B and re n i 7 number 300 0921 an 2 Move operation selector switch to STOP on 10099078 engine control fortwo wire starting AT cabinet ai with the 24 volt time delay module 300 tor three wire start ng 3 Disconnect the starting batteries 11 if module 9 is a 2 to 3 wire converter number 300 Power 24 Redistribution or publication of this document Generation by any means is str
27. normally closed contact connects to terminals 2 and 3 The K2 auxiliary contacts S6 have a normally open contact connecting to terminal block TB9 terminals 4 and 5 and a normally closed contact connecting to terminals 5 and 6 EXERCISER CLOCK The exerciser clock starts and stops the generator set automatically for periodic test and exercise operations without load The exerciser clock is con nected to lines A and B through disconnect plug terminals X and Y See drawing 626 0075 With 480 and 600 volt systems the exerciser is connected to a step down transformer Cam operated switch contacts M1 3 5 connect battery positive to the remote start terminal RMT The M1 contacts are shown in the normal position After the operator selects the desired exer cise periods the exerciser clock automatically exer cises the generator set Redistribution or publication of this document by any means is strictly prohibited Generation rua 626 0106 SCHEMATIC DIAGRAM zz 208 240v 307 0498 C 6 Lew PARTS LIST CESCRIPTION ory TERMINAL BLOCK MARKER STRIP HARNESS DISC PLUG 30 225 TO TO 8 _ HARNESS DISC PLUG 400 N LOAD K2 GEN A RECEPTACLE TRANSFER D t HARNESS CABINET 50 225 c SWITCH 3 HARNES
28. 4 8 for control groups 20 25 6A 36D 36D Measure K3 A B voltage for control groups 10 15 or K3 1 2 voltage for control groups 20 25 If it is 9 volts DC or greater the coil is probably open Replace relay g Power 48 Redistribution or publication of this document Generation by any means is strictly prohibited E Automatic transfer switch delays transferring load to line until generator set stops after normal power outage 1E Do relay contacts K3 6 9 close for control groups 10 15 or contacts K3 3 5 close for control groups 20 25 as relay K3 picks up when the normal source voltage returns 2E Clean K3 contacts Does this correct problem Replace relay K3 v Generator set starts during normal service 1F Is control panel disconnect plug properly inserted into g receptacle 2F Does automatic transfer switch have an exerciser clock 3F 5 exerciser clock turned to the exercise period 4F Record pick up voltage dial settings with small pencil marks on voltage sensor modules 1 2 and 3 only one in position 1 for single phase AT Turn pick up voltage knobs to 90 or below Does generator set stop after time delay After test return knobs to original settings Sr Recheck the normal line voltage and output voltage of transformers T2 T4 and T5 for tower than normal readings Make sure voltage sensors are set for correct pick up voltage 6F Are modules 13 14 and 15 overvol
29. 7 16A 12D 12D Repiace motor timer if it is stalled does not time out Power 15 Generation by any means is strictly prohibited Redistribution or publication of this document Automatic transfer switch delays transferring load to line until generator set stops after a power outage 1E Does AT have a retransfer time delay K10 2E Has time delay completed delay period Time delay expired if AC voltage present between terminals K10 6 and K10 7 with generator set running K4 energized 3E Does transfer switch retransfer load to line if terminal K10 8 is jumpered to K10 7 4E Repair or replace retransfer time delay K10 Do relay contacts 5 6 contacts 3 4 for 480 or 600 volt system close when the normal source voltage returns GE Clean K3 contacts Does this correct problem Replace relay K3 g Power 16 Redistribution or publication of this document d Generation by any means is strictly prohibited F pi Power Generator set starts during normal power service Is operation selector switch S1 positioned at NORMAL Is control panel disconnect plug inserted completely into receptacle Does automatic transfer switch have an exerciser clock Is exerciser clock turned to exercise period Is rated AC voltage present at transfer switch line terminals Does AT have voltage sensor modification Record pick up voltage dial settings with small pencil m
30. 8 TB7 8 drawing 626 0106 K1 mechanically held closed contact to energize K1 trip coil K1 TC The K1 trip coil operates to release the mechanically heid mechanism and to close contacts K1 IC Con tacts K1 IC energize the K2 closing coil from generator side line B to close the main K2 contacts connecting the load to the generator side Momentary Power Outage A very short duration power outage or dip on normal line voltage can drop relay K3 drawing 626 0445 Contacts K3 1 7 close to signal the start stop time delay module 7 to start timing However ifthe voltage dip or power outage is shorter than the time delay and the start up time of the generator set normally closed contacts K4 2 8 will bypass any time delay in retransfer to re energize relay K3 through the voltage sensors to keep theload on the normal line Contacts K3 1 7 open to reset the start stop time delay AREA PROTECTION Onan automatic transfer switches have provisions for connecting area protection equipment The normally closed output terminal of the area protec tion equipment connects to TB1 4 and 5 drawing 626 0445 A jumper between TB1 4 and 5 must be removed during wiring connections before the protection equipment will operate the circuit The area protection equipment opens the circuit between TB1 4 and 5 which removes the AC input voltage from voltage sensor module 1 12 15 Voltage sensor module 1 opens the circuit through contacts
31. 8 10 Line interposing relay is de energized as described under Power Outage Power When the area protection equipment closes the circuit between TB1 4 and 5 drawing 626 0445 again the voltage sensor module 1 closes a circuit through terminals 8 and 10 to pick uplineinterposing relay K3 again as described in Restoration of Normal Line RESTORATION OF NORMAL LINE When normal line power returns it energizes transformers T2 T4 and T5 drawing 626 0445 Transformer output voltage from terminals X1 and X2 feeds voltage sensor modules 1 2 and 3 Modules 1 2 and 3 contacts 8 10 close to complete the circuit from ground to relay K3 and to transfer retransfer time delay module 8 terminal 8 Module 8 starts timing because it already has battery positive from auto manual switch S3 contacts K6 1 7 voltage module 5 4 8 switch S1 2 3 and from terminal TB1 B When the time delay ends module 8 connects from terminal 2 to terminal 6 to pick up relay K3 Normally closed contacts K3 1 7 open to remove battery positive from start stop time delay module 7 which initiates the time delay in stop Also contacts K3 6 9 close the circuit from plug P1 terminal W receptacle J1 W drawing 626 0106 to transfer switch contacts K2 IC transfer switch contacts K1 CS through the K1 CC closing coil to terminal A on the lineside Transfer switch K2 contacts open and K 1 contacts close to connect the load to the line
32. AC line voltage from the automatic transfer switch Otherwise the transfer switch has high voltages and presents serious shock hazard Remove the twist lock disconnect plug and pull control accessory panel open 400 ampere AT only Remove the one screw from the inside center support for the left cabinet door and open Remove the one screw on top and one screw on bottom from inside the meter iamp panel flange Swing the meter lamp panel outward Disconnect the meter lamp panel wire leads from and TB8 if present See Figure 2 Remove the four nuts and washers holding the meter lamp pane on the left wall of the cabinet and remove the meter lamp panel Mount the new meter lamp panel on the cabinet using the same four nuts and washers TERMINAL BOARD T87 SENE Aj jj TERMINAL BOARD TBS 7 N FIGURE 2 TERMINAL BOARD FOR METER LAMP PANEL WIRE CONNECTIONS Power Generation toh o i PE DIA 1 Redistribution or publication of this document by any means is strictly prohibited CHANGING CONTROL ACCESSORY PANEL Panel Groups 10 15 and 20 25 12 Connect the wire leads as marked from the meter lamp panel wiring harness to terminal blocks and TB8 if present 13 Close the meter lamp pane and secure the top and bottom with the two screws from the other 1 Open automatic transfer switch cabinet door met
33. AMP TB7 Il TRANSFER SWITCH CABINET ASSY C t AUXILIARY CONTACTS LINE GEN SIDE CONTACT CONTACT CONTACT CABINET LESS METER PANEL S5 56 RATING T89 2 9 5 S ZOVAC wn TE9 I t Ars TB3 4 3A 240VAC rz T83 3 9 5 ale H 1 55 0 e 55 N O N G 22 WAS 58 2531 6 997 7 12 TB7 10 SS N C 95 D 99 127 d r S6 N O wa4sS 205 AMP x A 9 C FRONT VIEW QF S6 N O N C B ADDED 98 2799 SEE TRANSFER SWITCH 56 pe pens 336 M s NOTE TO LOAD 2 30 225 Oiy SiGm GF Misarapulln Ji nus J ALD WA KI 5 TRANSFER SWITCH CABINET ASSY 6 NE DIAGRAM 209 240 480 60CV Generation E So 26 0006 2 Redistribution or M of this document by any means is strictly prohibited 4W 50 60Hz Power Generation 6 AG A3 A2 Al WIRING DIAGRAM 62 0445 96 J2 JI REAR VIEW OF SWINGING PANEL AIS T2 Of 2 B TI Xt T3 X2 i51 T5 x2 151 74 x2 TO4 It distz T5 8 340 112 KEYU2V T3 XI 124 T5 x1 124 T4 x T2 XI 18 315 2 793 19 IOF J2 6 10 J 0 104 20 14 14 4 8 3 6 81 23 10 42 0 181 4 KEY B KEY 6T KEY KEY T 3 7 J4 8 443 4 4 7 1 1 TERI TB3 5 31 183 6 3l T53 2 TB3 18 2 TB6 2 TBU 7 Dd 445 Alt AT i23 usn JT 13 TDG 3 tb 214 03 20 T2236 m 34 12 TB
34. FOR 600V CONNECT I9 WIRE TRANSFORMER AS FOLLOWS 240V FI 2 240v 13 784 15 Fi 2 3Q 0V HH 440V ZOBV H6 Fi 2 300 H8 240V HT 240V H3 208 COM HI 4 15 TB4 15 20 ADD OVER O UNDER FREQUENCY SENSING REMOVE JUMPER BETWEEN 183 9 Ii THIS INFORMATION IS FOR MANUFACTURERS USE ONLY MODEL 208 240V mre 3 565 03 08 3 FOR 2 BATTERY CONNECT WIRE MARKED 2 5 RI 2 3 BETWEEN TI X2 RI 2 AT D AT FOR 24V BATTERY CONNECT WIRE MARKED TI X2 X3 RI 2 3 BETWEEN TI X3 4 Ri 3 C 4 TO ADD AREA PROTECTION EQUIPMENT OR REMOTE TEST TRANSFER SWITCH REMOVE JUMPER BETWEEN 4 5 5 REMOVE JUMPER BETWEEN 4 7 9 JUMPER BETWEEN TB4 5 amp 7 7 THIS CONTACT SYMBOLIZES A SOLID STATE SWITCH THAT CLOSES WHEN VOLTAGE 15 NORMAL AI A2 AS A A4 Power Generation AS FOLLOWS WIRE IN PACKAGE S PARTS LIST REF DES Pant DESERETEN 5 2 5 300 0700 3 UNDER VOLTAGE SENSOR LINE A4 500 0700 C 1 UNDER VOLTAGE SEHSOR GEN As soc oer MODULE VOCTAGE tev CT soc omam MODULE 24V TO l2V CONVERTERIAT AG s60 0937 MODULE BLANKISPAME POCOTIMREFICI 1 JBATTERY CHARGER 2 AMP IPV AT amp E poo 0or9 REFC BAYTERY CHARGER 2 AMP 24V AT C Ay 300 1646 1 BYPASS PLUG
35. HELD LINE SIDE TRANSFER SWITCH Power Generation Redistribution or publication of this document by any means is strictly prohibited 2 Remove the screw holding the stationary ar mature and coil assembly 3 Slide out the stationary armature and coil assembly 4 Remove the defective coil from the stationary armature and replace with new coil 60 through 100 Ampere Transfer Switch 1 Disconnect the coil lead wires 2 Pull off the hairpin shaped retaining clips holding the control rod and slide out the control rod needle nose pliers 3 Slide out the stationary armature and coil assembly 4 Remove the defective coil from the stationary armature and replace with new coil 200 225 and 400 Ampere Transfer Switch 1 Disconnect the coil lead wires 2 Remove the capscrews mounting the coil and statioriary armature to the case 3 Pull out the assembly 4 Remove the defective coil from the stationary armature and replace with new coil MECHANICAL LATCH AND CUTOUT SWITCH The latch mechanism and coil disconnect switch must be adjusted to open the main line circuit just as the contacts reach the closed position if the main coil pull in circuit is not broken coil hum will result If the coil disconnect switch opens before the transfer switch contacts are closed the contacts will chatter Latching Mechanism Adjustments Adjust the latching mechanism for positive locking by
36. INSP Qc TOLERANCES UNLESS cnet SPECIFIED TEST PR CEDURE AN 1MacE wee L 3 Exc wa OT quta ue BATTERY 539 Olb4 Corporation 1 7 LANE FLOAT CHARGER Friede is ol thin rgh it exiended lo aiher Power Generation d Redistribution or publication of this document by any means is strictly prohibited 2390188 TEST PROCEDURE T PLUG 12 BATTERY VOLTAGE SENSOA 3800758 INTO TEST 2 TUAN HIGH ADJUSTKEHT TO MAXIMUM CLOCKWISE POSITION AND LOW AQJUSTWENT MINIKUM COUNTEACLOCKRISE POSITION 3 SET TRE DC POWER SUPPLY VOLTAGE 12 3 05 VOLTS LAMPS 052 AND 054 SHOULD LIGHT LAMPS 051 053 055 ANO OSE SHOULD BE DARK 4 TURN LOW AUJUSTMENT TO THE RIGHT OR CLOCKWISE UNTIL 055 LO BAT VOLTS LAMP LIGHTS LAMPS 052 053 055 SHOULD LIGHT LAMPS 051 054 056 SHOULD REHAIN OARK 5 VARY DC POWER SUPPLY VOLTAGE UP 0 2 YOLT DOWH O Z FROM 12 3 VOLTS LAMPS 053 054 AND 059 SHOULD GO OFF AHG AS VOLTAGE CHANGES 6 TURN DC POWER SUPPLY VOLTAGE UP 13 7 4 05 VDLTS LAMPS 052 AND 054 SHOULO LIGHT LAMPS 051 859 055 ANO 056 REMAIN DARK 7 TURN LOW ADJUSTMENT CLOCKWISE UNTIL 055 LAWP LIGHTS LAMPS 9 2 053 AND 055 SEQULO LIGHT LAMPS DSI 054 AND 056 REMAIN DARK TURN ADJUSTMENT COUNTERCLOCKWISE UNTIL 056 VOLTS LAMP LIGHTS LAMPS 051 853 055 AN
37. KI3 LZ MAME FOR 240V GOHZ WIRE TO K7 LI WIRE R4 1 TO Ki3 Ll FOR 208 SONZ WIRE K9 7 TO K7 LI R4 I TO KI3 LI FOR 240V 5OHZ WIRE TO R5 BETWEEN 9 7 K7 LI TORG BETWEEN R4 1 amp KI3 LI CONTROL ACCESS PANEL In 307 0724 WAS 60 045 4 21 78 WIRING DIAGRAM gus 507 1419 WAS GO H aii haye 208 240 REM KIO 307 0723 WA IS 4W 5O 60 Hz 626 0175 C Power Redistribution or publication of this document Generation by any means is strictly prohibited 626 0164 REAR VIEW OF METER PANEL 511 912 NORMAL EM ERGEN Ud TU 32 Ti2 XI 112 DSI3 LO VOLT CY L X2 0514 BAT VOLT T87 5 TB 4 094 2 Far 3 0513 2 0515 0516 OVERCAANK 0516 2 TB7 2 MI2 TB 6 fae Power Generation SCHEMATIC m LEFT SIDE OF CABINET _ j IN m a BOECIN 22 0114 NOTE l Le AS FOR 550 7 19 ah 2 FOR 208 CONNECT Tar 3 7 8 TOTI2 9 FOR 240 TB7 I0 4 T87 8 0112 10 FOR 4BOV CONNECT TB7 IO TOTII 5 TB7 8 TO Ti2 Il FOR 600V CONNECT 7 10 TO T1 6 TB7 B TO 2 12 2 USE RESISTOR WITH RUNNING TME METER ON 600V GOHz ONLY 1 338 0883 338 0661 338 0659 301 3868 98 2415 98 2445 METER LAM
38. Step 10 Otherwise proceed to Step 8 15 Move operation selector switch diat 8 Insert small screwdriver through the 16 plug and close the con RETRANSFER opening lower opening in the TRANSI front panel of the transfer retransfer time delay 17 Reconnect the disconnect plug module Turn clockwise in small increments to 18 Move the operation selector switch to REMOTE increase the time delay counterclockwise to on engine control for two wire starting or to decrease the time delay NORMAL in cabinet for three wire starting 9 Repeat Steps 3 through 8 until the desired time whichever applies delays are obtained 19 Return selector switch to desired position 10 Move the selector switch to WITH LOAD if you WITHOUT LOAD or WITH LOAD want the generator set to assume load during 20 Close the cabinet door 36 Redistribution or publication of this document by any means is strictly prohibited LINE INTERPOSING RELAY K3 er 27 ay Mm mage REAR OF CONTROL ACCESSORY PANEL GROUPS 10 THROUGH 15 ONLY BENE RELA vee ING Y K4 REL J 3 i 4 Ts 22 d 5 LT i a PA 2 pe T pr 4 2 Lm a ease adem rae rem ms ob m FIGURE 17 LOCATION OF INTERPOSING RELAYS Retransfer Time Delay Spec A and B One of two retransfer time delays can be used to provide O to 30 minutes time delay on retransfer retransfer
39. below the pick up voltage This setting determines the voltage at which load is transferred from the generator to the normal power source A setting of 5 percent for example would give a 7 volt differential from 135 volts pick up voltage from Step 3 Drop out voltage is then 135 7 128 volts 5 After settings are finished move the operation selector switch on the engine control to REMOTE for two wire starting with AT C or AT D control or move the operation selector switch inthe AT E cabinet to NORMAL for three wire starting whichever applies 6 Close the cabinet door BATTERY FLOAT CHARGE For the following adjustments fully charged battery a hydrometer and an accurate voltmeter 1 2 percent accuracy are needed Onan recommends float voltages of 13 3 volts for nominal 12 volt or 26 6 volis for nominal 24 volt lead acid batteries 14 0 to 14 5 volts for 10 cell nickel cadmium batteries or 28 0 to 29 0 volts for 20 cell nickel cadmium batteries ead acid battery only During the first few weeks of operalion the batteries should be checked periodically with ahydrometer A high specific gravity bubbling of electrolyte and loss of water indicate excessive float voltage A drop in specific gravity indicates insufficient float voltage 32 Redistribution or publication of this document by any means is strictly prohibited Generation 1 Connect the fully charged battery verify charge condition with
40. document by any means is strictly prohibited Onon Onan Corporation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 ONAN 612 574 5000 International Use Telex 275477 Fax 612 574 8087 Onan a registered trademark of Onan Corporation a Power as Redistribution or publication of this document Generation by any means is strictly prohibited
41. from TB1 B through selec tor switch S2 1 2 to the remote start terminal TB1 RMT The generator set cranks and runs Three Wire Starting Start time delay relay K7 drawing 626 0175 begins its time delay When the time delay ends contacts K7 1 5 close to connect battery negative from TB1 1 through selector switch contacts S2 1 5 M1 4 5 K7 1 5 K4 2 1 K5 1 2 to TB1 H and TB1 3 The generator set cranks and runs Power _ Generation The AC running time meter is energized whenever the generator set operates Generator lines A and B supply generator power through terminals TB 6 and 7 drawing 626 0106 and to running time meter terminals M12 1 and 2 Generator output voltage completes a circuit from the output line A drawing 626 0106 6 6 drawing 626 0075 6 11 and 12 relay resistor TB6 7 drawing 626 0106 to generator output line B Relay K4 is energized drawing 626 0075 to close contacts 4 3 4 and open contacts 4 1 2 and K4 5 6 A circuit is now complete from TB6 6 through contacts K4 3 4 transfer time delay K13 TB6 7 drawing 626 0106 to generator line B Transter time delay K13 is energized and starts its time delay cycle drawing 626 0075 When the time delay ends transfer switch coil K1 TC is energized from generator line B drawing 626 0106 through normally open K1 contacts TB7 8 TB6 8 drawing 626 0075 closed 1 3 K13 1 5 closed c
42. is strictly prohibited p di Eh s 4 4 99 FORM Power Generation RELAY 307 1056 g B A NOTES 1 PLUG 24V T 0 START STOP 300 1080 C INTO TEST FIXTURE 24 28VOC 7 K A 4 START STOP GRN Q RED USE LAMPS THAT ARE COMPATARLE WITH BATTERY OR POWER SOURCE USED FOR TEST 300 1060 IC 539 0371 8 TQ os DFO cne TOLERANCES UNLESS OTHERWISE OACIMALS 4 Abe gm ot 44 mr Ise 539 0281 ha h d rr 1t 1 tartines al tins aatre tern At Fa io 539 0371 55 628 UPSD OWS SAME DTD 4 4 77 W CUG AI ISION 2 APPLY 24 TD 28 VDC 3 SET ALL SWITCHES IN 0 POSITION 4 MEASURE TIME DELAY 41 4 2 al 12 START CLOSE SWITCH STOAND MEASURE TIME OELAY BETWEEN SWITCH CLOSURE AND RELAY PECKUP MEASUREO 9 SEC ISEC STOP OPEN SWITCH SAND MEASURE BELAY BETWEEN THE SWITCH OPENING AND RELAY DROP OUT TIME MEASURED 8 SEC ISEC FACTORY SET TIWE DELAY START RESET SWITCHES 1 4 1 0 1 1 ON DFF QN ON AND MEASURE DELAY TIME MUST EXCEED 5 MIN STOP RESET SWITCHES 5 8 1 D 1 i1 ON OFF GN ON AND MEASURE TIME DELAY TIME MUST EXCEED 5 MIN DESC
43. is strictly prohibited 27 6 to 29 0 volts for the 20 cell nickel cadmium battery 4 Insert a small screwdriver into the LOW opening of battery voltage sensor module 10 for adjusting potentiometer R17 Adjust to the on off point for the LO BAT BOLT lamp The lamp must stay off 5 Pull out the battery charger module 6 The lamp must light when the battery terminal voltage drops to 12 6 volts for the 12 volt battery 25 2 volts for the 24 volt battery 12 6 volts for the 10 cell nickel cadmium battery or 25 2 volts for the 20 cell nickel cadmium battery 6 Insert battery charger module 6 back into its normal position The LO BAT VOLT lamp must go out as the terminal voltage returns to values listed in Step 3 7 Disconnect the voltmeter from the battery ter minals 8 Close the cabinet door OVERCRANK TIME AT E ONLY The following adjustment applies only to control accessory groups 10 through 15 and 20 through 25 Overcrank settings are made at the factory for approximately 75 10 seconds cranking To adjust PROGRAMMED TRANSITION Both programmed transition time delays can provide 1 to 300 seconds of no power to loads during transfer or retransfer of transfer switch operation For adjust ment of either time delay use the following procedure 1 Open cabinet door of automatic transfer switch 2 Move the operation selector switch to STOP in AT cabinet for three wire starting on engine cont
44. load from the normal line and closes the K2 contacts to connect the load to the generator side To end the test and retransfer the load back to the normal line movetest switch St to NORMAL drawing 626 0445 This connects battery positive from TB1 B S1 2 3 M1 4 5 voltage module 5 4 8 contacts 1 7 switch S3 1 2 to transfer retransfer time delay 8 terminal 2 Module 8 starts timing because it already has battery negative from modules 1 2 and 3 contacts 8 10 When the time delay ends module 8 connects B from terminal 2 to terminal 6 to pick up relay K3 Relay contacts K3 2 8 open break the circuit through TB6 8 drawing 626 0106 and 7 8 to de energize the K2 transfer switch coil Relay contacts K3 1 7 drawing 626 0445 open to de energize start stop delay module 7 which initiates stopping Relay contacts K3 6 9 close the circuit through plug P1 W receptacle J1 W drawing 626 0106 K2 IC contacts and K1 CS contacts to energize the 1 closing coil The K2 power contacts open to dis connect the generator from the load and K1 power Contacts close to connect the load to the commercial power line The mechanical latch on line side of the transfer switch locks the contacts closed and dis connects the K1 closing coil CC Start stop time delay module 7 contacts 2 21 drawing 626 0445 open afterthe time delay to de energize start relay K7 Power Generation Contacts K7 4 7 open to remove B from t
45. of load to commercial power line Both have similar adjustments See the OPERATION section for operation description The one retransfer time delay shown on the left in Figure 18 has two lamps POWER ON and TIM ING and a time adjustment knob To set the delay turn the adjustment knob clockwise to the desired retransfer delay time Shown on the right in Figure 18 is theotherretransfter time delay It has one lamp POWER ON and atime adjustment knob The adjustment knob has a black pointer and a red time remaining indicator pointer Turn the adjustment knob clockwise until the black pointer aligns with the desired time delay Preheat Time Delay The preheat time delay module 16 for diesel generator sets with 3 wire starting is adjustable from 5 to 60 seconds To changethe delay follow these instructions n Power Generation 10 Open the cabinet door of the automatic transfer switch Move the selector switch to WITHOUT LOAD Move the test transfer switch to TEST With a stopwatch or watch with a second hand measure the amount of time the small lamp on module 16 preheat time delay module lights before engine cranks Move the test transfer switch back to NORMAL If time delay for preheat is set as desired proceed to Step 9 If a different time is desired proceed to Step 7 Insert a small screwdriver through the PREHEAT opening in the front panel of preheat time delay module 1
46. particular application requirements Use settings which give load protection and yet will avoid nuisance load transfers 1 Open the cabinet door 2 Move the operation selector switch to STOP on engine control for two wire starting with AT C or AT D control or in cabinet for three wire starting with AT E control 3 Turn the PICK UP VOLTAGE knob to the desired pick up voltage voltage at which load is transferred from the generator set to the normal power source A setting of 108 volts for example gives a pick up voltage which is 90 percent of the nominal voltage for a 120 volt system 4 Turn the DROP OUT DIFFERENTIAL knob to the desired percent deviation below the pick up voltage This setting determines the voltage at which load is transferred from the normal power source to the generator set A setting of 15 percent for example would give 16 volt differential from 108 volts pick up voltage from Step 3 Drop out voltage is then pick up voltage minus the differential voltage 108 16 92 volts 5 After settings are finished move the operation selector switch on the engine control to REMOTE for two wire starting with AT C or AT D control or move the operation selector switch inthe AT E Power generator set A setting of 135 volts for example gives a pick up voltage which is 113 percent of the nominal voltage for a 120 volt system 4 Turn the DROP OUT DIFFERENTIAL knob to the desired percent deviation
47. switch closure Power 4 Redistribution or publication of this document e Generation by any means is strictly prohibited B Automatic transfer switch fails to connect load to generator set MEN when set runs during test with load or a normal power outage YES _ 1B Is generator output near rated voltage 2B 2B Does automatic transfer switch have NORMAL and EMERGENCY indicating lamps 3B 4B 3B Is EMERGENCY lamp lit 24B 5B 4B Is rated AC voltage present between TB7 8 and TB7 12 30B 5B 5B Does transfer switch operate to close generator side when voltage sensor module 4 pick up voltage knob Is turned to minimum counterclockwise 6B 7B 6B Is input voltage to transformer T3 connected to correct primary voltage tap to give nominal 40 volts AC on T3 X1 X2 7B 7B Does transfer switch operate when voltage sensor module 4 is replaced by bypass plug or if K4 terminal A K4 terminal 1 for control groups 20 25 is jumpered to ground 8B 9B 8B Replace voltage sensor module 9B Is plug in module 8 a transfer or transfer retransfer time delay 10B 12B 10B Does transfer switch operate when transfer time delay module 8 is replaced by a bypass plug or if K4 terminal B K4 terminal 2 for control groups 20 25 is jumpered to TB1 7 11B 12B 11B Replace time delay module 8 12B Is voltage on K4 A B on K4 1 2 for control groups 20 25 above 9 volts DC 18 13B 13B Is
48. the time delay indicates the preset delay The red pointer indicates the delay time left in operation 3 Close the cabinet door RETRANSFER TIME DELAY STOP TIME DELAY e PREHEAT o D TIME DELAY START TIME DELAY TRANSFER TIME DELAY REP e e CONTROL ACCESSORY o FIGURE 19 START AND TRANSFER TIME DELAY RELAYS Power PANEL FIGURE 20 STOP AND RETRANSFER TIME DELAY RELAYS 38 Redistribution or publication of this document by any means is strictly prohibited Generation GA g i gt JF es TRANSFER SWITCH 7 WARNING Due to the serious shock hazard never touch the transfer switch unless all power is remov ed from the automatic transfer switch Also set the operation selector switch to STOP and disconnect the generator set starting batteries TRANSFER SWITCH DESCRIPTION The following description is for a mechanically held ine side transfer switch Line contacts are closed and locked in the following manner Figure 21 The line side main coil pulls the contacts closed While the contacts are closing a mechanical latch engages the contact control rod and locks the contacts closed At the same time an arm on the mechanical latch actuates the coil cutout switch microswitch which opens the main pull in coil circuit The contacts have been closed locked in place and power removed from the main coil simultaneously To open
49. transformer T2 supplied from lines A and B through terminals X and Y of the disconnect plug drawing 626 0106 disappears Voltage at terminals T2 X1 and T2 X2 goes to zero drawing 626 0445 With zero input voltage to voltage sensor module 1 contacts 8 10 open to de energize line interposing relay K3 This completes a circuit to connect battery positive from the B terminal TB1 B through voltage module 5 18 16 through 1 7 toterminal 9 of the start stop time delay module 7 After a time delay module 7 energizes relay K7 through start suppressor control 21 16 20 and module 7 21 2 Relay K7 4 7 contacts close to connect from TB1 B to the remote terminal TBi RMT Two Wire Starting The battery positive on the remote terminal RMT signals the generator set to start Three Wire Start The B signal on the remote terminal feeds terminal 10 on the 2 to 3 wire start converter plug in module 9 With battery positive on terminal 10 module 9 closes the circuit between terminals 15 and 4 grounding Output terminal 3 It also opens the generator set stop circuit by removing ground from TB1 2 The generator set starts and runs The AC running time meter is energized wheneverthe generator set operates Generator line A drawing 626 0106 supplies power through TB7 6 drawing 626 0164 to running time meter M12 1 Generator line B drawing 626 0106 supplies power through TB7 7 drawing 626 0164 to running ti
50. until the voltage reaches approximately 14 5 volts for a 12 volt Jead acid battery 29 0 volts for a 24 voit lead acid battery 15 5 volts for a 10 cell nickel cadmium battery or 31 0 volts for a 20 cell nickel cadmium battery Since these are suggested high battery voltage settings consult the battery manufacturer for the recommended alarm Settings 6 Insert a small screwdriver into the HIGH opening of battery voltage sensor module 10 for adjusting potentiometer R9 Adjust to the on off point for the HI BAT VOLT lamp Thelamp must stay lit at this voltage 7 Unplug or turn off the battery charger The lamp must go out as soon as voltage drops a few tenths 8 Turn on battery charger The lamp must light as voltage returns to value given in Step 5 High battery voltage lamp does not light for normal operation 9 Disconnect the battery charger and voltmeter 10 Insert battery charger module 6 into control panel 11 Close cabinet door Low Battery Voltage Alarm Setting 1 Open the cabinet door of the automatic transfer switch 2 Connect a DC voltmeter to the battery terminals 3 For the alarm setting the battery should be charged unti the voltage reaches approximately 12 9 to 13 3 volts for the 12 volt lead acid battery 25 8 to 26 6 volts for the 24 volt lead acid battery 13 8 to 14 5 volts for the 10 cell nickel cadmium battery or Redistribution or publication of this document by any means
51. voltage from TB1 GND to TB1 B equal to rated battery terminal voltage 148 36B 14B Is voltage from TB3 7 to TB3 16 equal to rated battery voltage 15B 36B 15B Is voltage from TB3 7 to TB1 6 greater than 9 volts DC 16B 37B 16B Is voltage from TB3 7 to TB1 7 greater than 9 volts DC 17B 38B 17B Is voltage from TB3 7 to K4 B to K4 2 for control groups 20 25 greater than 9 volts DC 18B 39B 18B Is relay K4 energized and are contacts K4 4 7 contacts K4 4 6 for control groups 20 25 closed properly 20B 19B 19B Replace relay K4 B 20B Is rated AC voltage present on transfer switch generator terminals 21B 21B Are contacts K3 8 2 contacts K3 4 8 for control groups 20 25 closed to bring rated AC voltage down to TB6 8 Measure for rated AC voltage between TB7 8 and 7 6 23B 22B 22B Replace relay K3 23B Are K1 line side contacts open 27B 24B Power 43 Redistribution or publication of this document Generation by any means is strictly prohibited B Continued _ _ YES ne biennial 24B Jumper normally open K1 interlock contacts Does transfer switch operate 25B 25B Repair or replace normally open Ki interlock contacts 26B Is K1 trip coil open circuited or is trip coil mechanism obstructed 27B Does AT have a programmed transition time delay assembly located in rear of standard cabinet below transfer switch 28B 28B Does transfer switch operate if terminal TB11
52. y yA 65 Cee 5 4 B D R 7 W PRINTED CIRCUIT BOARD RECEPTACLE KEYING PLUG FIGURE 9 INSTALLATION OF KEYING PLUG Redistribution or publication of this document by any means is strictly prohibited ADJUSTMENTS See the TRANSFER SWITCH section for maintenance repair or adjustments of transfer switch mechanism LATCH AND LATCH PIN ADJUSTMENT If the control accessory panel will not close because the latch is above or below the latch pin on meter panel for 30 through 225 ampere AT s on cabinet center support for 400 ampere AT s perform the following 1 Open cabinet door of automatic transfer switch 2 Move operation selector switch to STOP in AT cabinet for three wire starting on engine control for two wire starting and disconnect starting battery 3 Remove AC line voltage from the automatic transfer switch Be sure to remove AC line voltage from WAR NING the automatic transfer switch and dis able the generator set Otherwise the automatic transfer switch presents a serious shock hazard PANEL WITCH ZELECTRIC PLANT POSITION REMOVE BESCONNECT C FORE EGPENING ZZPANEL 22 LATCH PIN EN CHECK ALIGNMENT WITH PLASTIC LATCH PLASTIC LATCH B252 CONTROL ACCESSORY 10 11 12 Remove the twist lock disconnect plug Completely open the control access
53. 15 and 20 25 Fora conversion from three wire 12 volt system toa two wire 24 volt system perform the Changing Con tro Accessory Panel DC System Voltage first then proceed to the following 1 Open the automatic transfer switch cabinet door 2 Move the operation selector switch on 2 to 3 wire converter module 9 to STOP 3 Disconnect the starting batteries 4 Remove AC line voltage from the automatic transfer switch Failure to remove AC power from the SAMNIO automatic transfer switch and to disable the generator set presents a serious shock hazard during this modification 5 Remove the wire leads between the engine con trol remote terminal block and the automatic transfer switch remote terminal block TB1 6 Remove 300 0928 2 to 3 wire converter module 9 and replace it with a 300 0937 blank spare module 7 Connect automatic transfer switch terminals TB1 B RMT and GND to the 2 wire start engine control 8 Restore AC line voltage to the automatic transfer switch 9 Connect the starting batteries Move the operation selector switch on the engine control to RMT 11 Close the cabinet door Redistribution or publication of this document by any means is strictly prohibited ADDING MODULE IN CONTROL ACCESSORY PANEL The following procedure applies only to control accessory groups 10 15 and 20 25 Whenever adding a plug in module in the control accessory panel where there previously w
54. 2 BATTERY VOLTAGE SENSOR ALARM SETTINGS ihe following adjustments apply only to control accessory panel groups 11 through 15 and 21 through 25 The high and low battery voltage alarm circuits monitor the condition of the battery charging system A battery charging malfunction lights one of the lamps to indicate either a failure to charge LO BAT VOLTS or battery overcharge BAT VOL T Ensuring proper function of both alarm lamps re quires careful setting of the potentiometers for both the low and high battery voltage sensing circuits Setting the alarm points requires a screwdriver DC voltmeter 1 2 percent accuracy preferred and a battery charger separate charger required for high battery voltage alarm settings Power Generation 33 You can build a test fixture as shown in ihe TROUBLESHOOTING section for making adjustments on the battery voltage sensor module rather than using the following procedures High Battery Voltage Alarm Setting Open cabinet door of automatic transfer switch Connect a DC voltmeter to the battery terminals Pull out the battery charger module 8 Connectaseparate battery chargertothe battery Using separate battery charger eliminates changing charger settings of battery charger module 6 for this procedure The separate baltery charger must have sufficient capacity for the particular battery 5 For the alarm setting the battery should be charged
55. 20 volts for AT D or and 40 volts for AT C Replace battery charger module 6 with new module rua Power 50 Redistribution or publication of this document d Generation by any means is strictly prohibited 2 X Aman l OVERCRANK lamp lights while generator set is running OT E only YES 11 5 generator output voltage near normal 21 E 21 Does undervoltage sensor module 4 have correct setting so that relay K4 energizes 3l 3l is there less than 2 volts DC present between TB3 18 and TB1 GND 41 41 Is relay K4 energized and does overcrank lamp go out if voltage sensor module 4 pick up voltage knob is turned to minimum counterclockwise 5l 6l 5l Is input voltage to transformer T3 connected to correct primary voltage tap to give nominal 40 volis on X1 X2 6l el Is relay K4 energized and does overcrank lamp go out if you replace voltage sensor module 4 with a bypass plug 7l 8l 71 Replace voitage sensor module 4 81 Replace 2 to wire converter module pi Power 5 Redistribution or publication of this document 2 Generation by any means is strictly prohibited Overcrank lamp lights without any engine cranking OT E only Has a power outage occurred Is control accessory panel disconnect plug removed Connect the disconnect plug move the selector switch on 2 to 3 wire converter module to NORMAL Lamp lights if power outage occur
56. 30 31 slowly until you hear relay K3 pick up With sensor module PICK UP VOLTAGE knob at 120 volts and DROP OUT DIFFERENTIAL knob at maximum lower the AC output voltage from the Multi Tester or variac until the voltmeter reads 108 volts Turn DROP OUT DIFFERENTIAL knob counterclockwise until you hear relay K3 drop out The knob should read approximately 10 90 percent of 120 volts 108 volts If not useasmall screwdriver to loosen the knob and reposition so it indicates 10 percent Set the PICK UP VOLTAGE and DROP OUT DIFFERENTIAL knobs at desired settings Decrease the voltage with the Multi Tester or variac until you hear relay K3 drop out Increase the voltage with the Multi Tester or variac until you hear relay K3 pick up Readjust the PICK UP VOLTAGE and DROP OUT DIFFERENTIAL knobs to give the desired pickup and dropout voltages Rather than reconnecting the voltmeter variac or Multi Tester for the other undervoltage sensors pull out the already calibrated module and replace it with one of the other undervoltage sensors Then perform the calibration procedures in this position After calibration is complete remove the dis connect plug Disconnect the Multi Tester or variac and voltmeter Reconnect the wire leads and install the plastic cover over the terminals Close the control accessory panel and reconnect TOP TRANSFORMER TERMINAL STRIP T2 1 COM T2 2 120 V T2 3 208 V T2 4 240
57. 4 i4 KEY I2V 42 12 86 3 K4 D E B2 6 42 18 T 1782 5 5 K5 7 24 19 182 4 Th4 20 Ta2 3 704 18 64 703 6 1 15 12 4 2 544 565 782 2 KEY 4 KEY J3 12 KEYi24V ya2 1 134 5 24K7 B T2 1 45 15 15 95 At AIT AIG 5 Ala AI T tay win Jib 19 113 294 19 14 174 49 0 157 T5 x2 151 T4 x2 i5 454 2 24 T5 x iz T4 xi I24 12 pare 0 J9 22 0 183 22 04 183 22 104 193 22 12 43 3 0 Ji 4 Bl J4 4 B Ji3 4 64 KEY 6 KEY 6 KEY 2 3 54 29 16 41 15 5 44 4 8 44 13 8 24V 3l 34 TAS 3 3 3 2t 9 1 BOTTOM VIEW OF BRACKET Kr sl 52 344 5 6 TB3 l2 7 8 9 Taita B J7 2 c K4 4 7 231 2 3 YBa r2 3 4 5 64184 12 K 244 5 61 53 3 4 5 6754 2 3 8 8 O7PI W T3 74 7 8 94 4 18 7 9 5454 1 20 Bj TB4 i Teza 8 4812 84 2044 _ BjTB4 5 TB6 B 784 19 CRI Fl 52 51 3 HT TB4 K3 6 T2 1 3 PI Y PK T4 1 K5 8 48 2 6 53 K6 7 E 7 i amp T K5 7 EOM 38 6 K5 A 83 9 j K A DI AR Titia 413 I 54 2 51 45 4 52 2 TB4 2 Mi 3 4 1685 15 KT 4 TB3 14 5 BI RMT 545 T84 5 TB4 22 K5 4 T3 4 9 10 12 K3 n 49 21 46 5 91 2 3 HIGH BAT CONTACT VOLT RATING LOW 2A e4VnC BAT 2 20VAC MI 2 ieee PI E K 5 7
58. 5 is jumpered to TB11 6 of time delay assembly 29B 29B Repair or replace K12 time delay 30B ls transfer switch mechanically held on generator side 31B 31B Does transfer switch operate if you jumper K2 CS cutout switch 32B 32B Replace K2 CS cutout switch 33B Does transfer switch operate if terminal TB7 7 is jumpered to TB7 12 _ 34B 34B Heplace normally closed K1 IC interlock contacts 35B Closing coil K2 CC is open circuited or switch mechanism is obstructed preventing transfer switch closure 36B Check for poor connection defective battery etc 37B Replace module 5 i 38B Check circuit from TB1 6 to TB1 7 it must be closed by a jumper or external circuit TUM 39B Replace module 8 with bypass plug Make sure circuit from J8 21 to J8 12 J8 22 to J8 12 for Spec A and B is closed Gra Power 44 Redistribution or publication of this document udi Generation by any means is strictly prohibited Automatic transfer switch fails to start generator set during a power outage YES 1C Is plug in module 9 of control accessory panel a 2 to 3 wire converter 300 0926 with selector switch set in NORMAL position 2 2 Push the module 9 reset switch If engine does not crank place module 9 selector switch in HAND CRANK position Can you start generator set with start switch on engine control 3C 3C Stop generator set and move module 9 selector switch to NORMAL
59. 6 Turn potentiometer clockwise to increase preheat time counterclockwise to decrease delay Make adjustments in small in crements Repeat Steps 3 through 7 until desired preheat time is obtained Move selector switch to desired position WITHOUT LOAD or WITH LOAD Close the cabinet door Redistribution or publication of this document by any means is strictly prohibited FIGURE 18 RETRANSFER TIME DELAYS TIME DELAYS CONTROL GROUPS 51 55 Start Transfer and Preheat Time Delays Onan has suggested settings of 1 to seconds forthe start time delay 2 to 5 seconds for the transfer time delay and 60 seconds for the preheat time delay All require the same adjustments for changing Settings and have time ranges of 1 to 300 seconds settings perform the following 1 Open the cabinet door of the automatic transfer switch 2 Turn the knob on the time delay clockwise to increase delay time counterclockwise to decrease the delay time See Figure 19 3 Close the cabinet door Stop and Retransfer Time Delays Suggested settings for these time delays are 5 minutes for stopping and 10 to 20 minutes for retransfer To change time settings adjustable from 2 to 60 minutes use the procedure following 1 Open the cabinet door of the automatic transfer switch 2 Set the time delay by turning the adjustment knob in the center of the delay See Figure 20 The black pointer on the face of
60. Caution This document contains mixed page sizes 8 5 x 11 or 11 x 17 which may affect printing Please adjust your printer settings CCOrding to the 5176 each page you wish to print of this document by any means is strictly prohibited Service witch 30 through 400 Amperes 962 0500 SPEC A C 8 79 Printed in U S A Power Redistribution or publication of this document Generation by any means is strictly prohibited SAFETY PRECAUTIONS This manual includes the following symbols to in dicate potentially dangerous conditions to the operator or equipment Read the manual carefully and know when these conditions exist Then take the necessary steps to protect personne and the equip ment WARNING Onan uses this symbol throughout this manual to warn of possible serious personal injury This symbol refers to possible equipment damage The automatic transfer switch has components with high voltages which present serious shock hazards For this reason read the following suggestions Keep the automatic transfer switch cabinet s closed and locked Make sure authorized personnel only have the cabinet keys Always move the operation selector switch on the generator set or automatic transfer switch to STOP disconnect the starting batteries of the generator set and remove AC line power to the automatic transfer switch before performing mai
61. D BSG SHOULD LIGHT LAMPS 052 AND 054 SHOULD BARK 8 RAISE OG SUPPLY VOLTAGE 15 4 05 VOLTS LAMPS 051 054 ANG DS amp SHOULD LIGHT LAMPS 052 053 DSS SHOULD DARK 10 TURN HIGH AUIUSTMENT CLOCKWISE UNTIL OSG DOES BARK LAMPS 052 AND 054 SHOULD LIGHT LAMPS 051 053 055 AND 056 SHOULD DE DARK 11 VARY DE SUPPLY VOLTAGE UP 0 1 VOLT AND DOWN 0 1 VOLT FROM 15 5 VOLTS LAMPS 051 052 AND OSG SBOULO GO OH AND OFF WITH VOLTAGE CHANGE 12 MAKE FINAL FACTORY AQJUSTMENT 2 SET HIGH ADJUSTMENT 50 OSG LIGHTS AS DC SUPPLY VOLTAGE 15 RAISED TU 14 5 VOLTS BOES DARK WHEN LOWERED 14 4 VOLTS b SET LOW BATTERY VOLTAGE 0 055 LIGHTS AS OC SUPPLY IS LOWERED 12 8 VOLTS ANO GOES AS VOLTAGE 1 RAISED 12 8 VOLTS a Power Generation WASP SSZA EEF7 WAS 552 1271 77 fad ee GI GNE 256 HI BAT VOLT 22 65 VOLTMETER PREFER ACCURACY IN t IE VOLT RANGE VM VARIABLE DC POWER SUPPLY USE LAMPS THAT ARE COMPATABLE WITH BATTERY OR POWER SOURCE USED FOR TEST 88 0 6 VEST CONNECTOR 33257107 TERMINALS 332442108 TRE en rux ercmenow Mart Ea DIVISION OF ONAN CORPORATION Minneapolis Minnesots 51 TEST PROCEDURE 2 6 16 72 V SENSOR I2V 2 72 p ATSD amp ATSE 8 559 0 88 31 1 the weefrianp hga wm
62. E DELAY 8 Move operation selector switch to REMOTE on engine control for two wire starting or NORMAL 6 Move the test transfer switch to NORMAL in for three wire starting whichever 7 With a stopwatch or watch with a second hand aL dn count the number Of flashes the bottom green 9 Move test transfer switch to TEST Generator set LED makes in 60 seconds Onan suggests coun will start and run ting for 60 seconds shorter intervals would give 10 With a stopwatch or watch with a second hand less accuracy for determining time delays Once measure time from instant generator set reaches retransfer timing is complete the red retransfer full speed until relay K4 contacts close If time LED will turn off and the green LED will remain on delay is correct or time you desire proceed to for the duration of the generator set stop delay Step 14 lf not proceed to Step 11 The following list gives the correlating pulses to 11 Insert a small screwdriver through hole in front time delays panel of transfer time delay module 8 Turn l clockwise in small increments to increase the Pulses 60 sec Time Delay min time delay counterclockwise to decrease the 50 5 time delay 25 10 12 Move the test transfer switch to NORMAL to stop 17 15 the generator set b zn 13 Repeat Steps 9 through 12 until the desired time 8 30 delay is obtained oH 4 14 Move the test transfer switch to NORMAL ime delay is correct or time you want procee to
63. GING PNL HOUSING CONNECT TS CABINET CONNECT TO REMOTE TERMINAL BLOCK ON PLANT 52 2 K7 5 6 5 d 52 MI 5 TO LOAD 8j TEST 15 b o TBi RMT sro 52 52 TBI 5 S ji K7 K3 9 RS Mi a 81 2 1 301 4687 B 2 PLATE COVERIVOLT SENSOR LL 301 4141 8 1 CHARGER CONTROL ACCESSORY GROUP 55 es ee EXERCISER CLOCK 535219486 START 1 300 SEC 503 0721 247 SFER j 300 SEC J wax 804 0275 QTY M coq Tu 247a NOTES STOP HiwAS 5801 8545 8 SAS ALL COMPONENTS SHOWN IN DE ENERGIZED POSITION LOCATION OF SI aS Te UNLESS OTHERWISE NOTED 9 UPDATED R5 Kia K6 L3 i PI 2 TO ADD AREA PROTECTION EQUIPMENT OR REMOTE TEST sor aay baste TRANSFER SWITCH REMOVE JUMPER 8 CONNECT TO TBI 4 5 NOTE 5 FoR SOUP vf Un 2 474 N D ADpED RS ERE 414 K3 6 4 3 TO ACTIVATE TRANSFER INHIBIT CIRCUIT REMOVE ORO JUMPER CONNECT TO 1 8120 c 02 50H p4ov E SROU MO WAS og 238 B REVERSE 163 52 wisi 2 2 74 X Y 4 AFTER TEST PLANT WILL RUN FOR DURATION OF TIME DELAYS FA Ke WAS 307 0 4 4455 5 TO CO
64. IHA Neve 303 Oky SLIDA 62 di 035199 S ISVLIDA 114405 21 SY 51u9 1 850 OS LIS v iN3N1S0f0Y 18012 3 1H 3 JONVHD 39Y1104 440 ONY HD 09 011095 850 ONY 250 IS Sany 51104 FE MOYA 1704 NADO ONY 1104170 df 33Y1704 414405 36 AUYA MEV 36 010085 950 550 ESO 150 54 1 18917 DInOHS 0 ONY 250 54491 80 5309 950 351439019 IMGIS TDY 0 38 1 0 5 550 CSO ZSE 4NYT 1 911 1 0 950 OMY 950 7150 54477 01 359v1704 114415 90 yuv 38 TmInOHS 950 ONY 250 54191 1817 GINDHS 950 50 ESO 150 54071 011 dir 51704 LYA 950 TIANA 351 4350178319007 HSUH SUV 850 PSO ISO 4877 1H511 OWOHS SSO ANY ESO 250 52811 7518017 47 950 11180 35 44019 IN3ISTTOY ROT MUNG 950 MY 550 ESO LSO 54491 1H313 GingHS 950 My 2S8 SJNYI 5110420 22 01 dh 38v110A 174402 83504 39 39YLWIA SY ONY 430 05 010045 SSO ONY PSO ESO 54807 1104 9 bc LIGA Z O MADO OHY 110A 270 3541704 116405 83804 20 NIYAYA DIDOHS DSO OXY 950 150 010085 SSG ONY ESO 7250 Sawy 518911 417 51104 199 01 550 TAHA 151415072 IHSId 201 04 IMZEISOICY 401 DINGHS 958 ONY SSG eso 7150 caer IH5 1 AWOHS 50 ONY 20 SuAY
65. ION The detailed operation description following is in tended as an aid in understanding and servicing the automatic transfer switch it gives two operation descriptions one for an AT with a solid state modular type control accessory panel control panel groups 10 through 15 and 20 through 25 and one for an AT with a relay type control accessory panel control panel groups 51 through 55 The descrip tions apply to typical models and might not directly relate to a model you are servicing Wiring diagrams referenced in the operation descrip tion appear at the end of this section Note each one has three parts a pictorial wiring diagram a schematic and a parts list Any model AT automatic transfer switch uses three schematic wiring diagrams One covers the meter lamp panel portion one covers the control accessory panel portion and one covers the transfer switch cabinet portion If you wish to follow the schematic wiring diagram as youread the operation description you will have to use and follow all three schematic wiring diagrams referenced in the text Operation description is written using only the schematic por tion of each schematic wiring diagram Redistribution or publication of this document by any means is strictly prohibited Generation AT S WITH CONTROL ACCESSORY GROUPS 10 15 AND 20 25 NORMAL OPERATION Under normal conditions the commercial line supplies the power to t
66. NNECT RELAYS K7 amp IU ZZ K3 5 FOP 2086 60 92 WIRE 9 TO K7 L2 WIRE R I TO Kt3 L2 n ONE Kart To TEMRE M I TO NE E ih ccnl DB C piat FOR 240V 50HZ WIRE BETWEEN K9 7 K7 L CER es 6 75 f aoB CDR R6 BETWEEN RA4 IAKIS LI P 12215742 307 0723 a 4 20 29 Hami CN Was 20 Lm 307 0729 leralera e WIRING DIAGRAM L was 62 CM 9 4 20 78 a a LET REVISION DATE SW 50 60 Hz 626 0175 626 0075 C Power m Redistribution or publication of this document Generation by any means is strictly prohibited 626 75 FARTS 1157 eee d I ET E EE ANTERON O TO LINE 8 c ___ 307 1083 8 i RELAY INTERPOSIMG LINE 240V CONNECT TO PLANT TERMINAL BLOCK V K7 IT __ 307 119 1 RELAY PHASE PROTECTION 206V SWINGING PANEL INSIDE VIEW OF TRANSFER SW CABINET OR SWINGING HOUSING PROTECTION 307 188 6 RECAY TiME DELAY ON STARTING 00 SEC ON DE ENERGIZATION sor335 a 1 MOUNTING PKG RELAY PNL x9 307 1419 A 1 RELAY ASSY TIME DELAY ON STOPPING Y jaFTER RETRANSFER 50760 TR TO69 MIN CN ENERGIZATION polo
67. P COMBINATION 6 CHARGE AMMETER que METER 0 1 SILKSCREEN METER PANEL 1 LABEL POWER SENTRY PARTS 1157 PART um SL er QE SCRIKT LAMP LO BAT VOLT IAV AT DAE A LAMP LO BAT 28V C LAMP HI BAT VOLT I4 V LAMP BAT VOLT 281 CI LENS EZEL ASSY LAMP OVERCRANK 144 CHARGER 0 2 METER RUNNING TIME T20VMBOOVKGOH METER RUNMNG TIME 240v 60Hz TER RUNNING OA s ETER RUNNING TI METER RUNNING TIME 460V 50Hz J ri TRANSFORMER ASSY STEPDOWN EE SS 3 HARNESS LAMPS NORMAL EMERGENCY o HARNESS LAMPS VOLTS fs OVERCRANK LAMP USE ON ONLY RUNNING TIME METER NORMAL amp EMERGENCY LAMPS BATTERY VOLTAGE LAMPS THIS INFORMATION 15 FOR MANUFACTURERS USE ONLY HERTZ VOLTAGE eo mov o os 60 208 240 02 09 10 so 05 i2 50 208 24ov 06 13 so o 4 o anop zov IC 2 2 WENT TO TB87 9 B AboEb 6007 To mie palay ahas mri Kor ry WILLY AT C AT 5 SPEC B 120 208 240 480 600 50 60Hz n Ones CORPORATION dau DIAGRAM 7 26 016412 Redistribution or publication of this document by any means is strictly prohibited
68. Place selector switch S2 on control accessory panel to WITHOUT LOAD and test transfer switch S1 to TEST Does generator set start 18C 4C Jumper TB1 B to TB1 RMT make sure that voltage from ground to TB1 RMT is equal to rated battery voltage Does engine crank 5C 5 Check circuit from TB1 B through control panel test transfer switch S1 2 1 and selector switch S2 2 3 to TB1 RMT for loose connections or open circuits 6C Jumper TB1 GND to TB1 3 Does engine crank 8C 7C Check all wiring and switches between B GND and terminal 3 on the generator set the B GND and terminal 3 on TB1 in the automatic transfer switch for an open circuit 8C Is plug in module 16 a preheat time delay module 10C 9 Replace 2 to 3 wire converter module 9 10C Remove wire lead from J16 19 Does engine crank 11C 11C Replace preheat time delay module 16 120 Is selector switch on engine control in REMOTE position 13C 13C Does generator set start run and stop with selector switch on generator set Return switch to remote position 150 14C Refer to the generator set operator s manual and service manual 15C Place selector switch S2 on control accessory panel to WITHOUT LOAD and test transfer switch 51 to TEST Does generator set start 18C 16C Jumper TB1 B to TB1 RMT make sure that voltage from ground to TB1 RMT is equai to rated battery voltage Does engine crank 17C 17C Check circuit from TB1 B through
69. R OF CONTROL ACCESSORY PANEL H __ Dx STEPDOWN TRANSFORMER T4 TAP CONNECTIONS Mr STEPDOWN TRANSFORMER T5 TAP CONNECTIONS 7 THRU 12 FIGURE 5 VOLTAGE CONNECTIONS FOR STEPDOWN TRANSFORMERS REAR OF CONTROL PANEL BATTERY CHARGER TRANSFORMER Ne CHANGE TAR A CONNECTIONS PER WIRING DIAGRAM E B149 FIGURE 6 BATTERY CHARGER TRANSFORMER AC CONNECTIONS Fd Power Redistribution or publication of this document d Generation 22 by any means is strictly prohibited we C 12 Move the operation selector switch to RMT on engine control for two wire starting or NOR MAL in cabinet for three wire starting whichever applies 13 Close the cabinet door CHANGING CONTROL ACCESSORY PANEL DC SYSTEM VOLTAGE This modification applies only to control accessory panels in groups 10 15 and 20 25 From 24 to 12 Volts Some control accessory panels do not have all theitems mentioned in the following procedures For example a group 10 panel does not have a battery charger module battery chargertransformer T1 charger resistor R1 high and iow battery voltage indicator lamps 0514 and DS13 etc if a panel does not have the mentioned item proceed to the next step 1 Open the automatic transfer switch cabinet door 2 Move operation selector switch to STOP on engine co
70. RESET DURING THIS STEP 3 INREBIT SET CRANK TIME FOR 5 10 SEC CLOSE SWITCH 52 OURIKG START 4 1 START LIGHT SHOULG OUT WREN 52 15 CLOSED AND SHOULD HOT LIGHT AFTER DELAY OPEN 52 9 2 REPEAT FOR 3 SAWE RESULTS 5 3 OPEN 51 52 53 AND CLOCK SWITCH 2020 6 lt 4 G CRANK PLATE SELECTOR SWITCH DN CONVERTER CRANK POSITION SOTH STOP AND START LIGHTS SHOULD OFF CLOSE CLOCK SWITCH QVERCRAHK LIGHT SHOWED GOME AFTEA TIME DELAY A 1 MEASURE OVERGRANK DELAY R 7 MAX 3 1 CLOSE LOGK SWITCH ANG SWITCH 1 STOP LIGHT GDES START LIGHT GOES N START LIGHT BDES DEF AND OVERCRANK LIGHT GDES ON AFTER TIME DELAY THIS TIME DELAY WUST BE GREATEA THAN 98 SEC 7 2 DPEN SYITCH 51 DPEN CLOCK SWITCH 9 ADJUST POT A 7 FOR 75 5 SEC TIME DELAY NOTE FOLLOW STEP 7 1 BUT ADJUST TO 74 35 SEC STOP POSITION PLACE SEITCH ON CONVERTER STOP POSITION STOP LIGHT SHOULD ON AND START LIGHT SHOULD OFF 9 1 RETURN SWITCH ON CONVERTER TO NORMAL POSITION OFEN ALL SWITCHES ON TESTOR TURN OFF POWER AND CIRCUIT 80450 PART 553 orv eeuixi DESCRIPTION MATERIAL PR DIVISION OF ONAN CORPORATION rrr 2 73 Minneapolis Minnesota pease ld ISH TEST PROCEDURE TEC TO 3 WIR ONY 539 0202 Redistribution or publication of t
71. RIPTION OR MATERIAL DIVISION OF ONAN CORPORATION Minneapolis Minnesota eee aix TEST PROCEDURE 24V ar 6 22 78 db AT PROGRAM TIMER 539 0281 E Redistribution or publication of this document by any means is strictly prohibited 539 0282 PEE NOTES du LI 2 BAT OR DC SUPPLY c 7 1 al T T tRansren 2 gt RETRANSFER USE LAMPS THAT ARE COMPATABLE WITH BATTERY OR SUURTE USED FOR TEST USE RELAY 30781058 FOR amp K2 USE DIODE 45744 FOR CRI amp CR2 TEST CONNECTOR A 332 2107 A TERMINALS A DECIMALS 2 1 The dengn on iua by jhe Oren of Oran thee nht ia ethers Power _ Generation Vu as 2 PLUG 12 V T 0 RETRANSFER XFR 30001188 INTO TEST FIXTURE APPLY 12 TQ 15 VOC TURN TRANSFER ADJ TD MINIMUM COUNTERCLOCKWISE POSITION MEASURE MINIMUM TIME DELAY 4 1 TRANSFER LOSE SWITCH 51 AND MEASURE TIME DELAY BETWEEN SWITCH CLOSURE RELAY PICKUP MUST BE LESS THAN 0 5 SECOND FACTORY SET TIME DELAY 8 1 TRANSFER TURN TRANSFER 0 CLOCKWISE TIME MUST EXCEED 15 SECONDS CLOSE SWITCH 51 AND MEASURE DELAY ADJUST FOR 2 5 0 5 SECONDS DELAY 5 2 RETRANFER CLOSE SWITCH S2 AND MEASURE RETRANFER LED PULSE RATE ADJ RETRANFER UNTIL LED HAS A PULSE RATE OF 18 PUL
72. S CABINET 460 208 240 307 0926 C 332 1698 MARKER STRIP 08 338 0678 B 1 HARNESS AUX CONTACT 30 225 D HARNESS AUX CONTACT __ CONTACT 400 Em a gt 307 0506 307 0581 C LABEL WITRSTAND RATING ac LABEL wITHSTAND RATING 60 LABEL WITHSTANU 00 LABEL WITHSTAND RATING 225 LABEL WITHSTAND RATING 400 98 2537 98 2534 98 2535 307 0507 600 307 0580 55 56 208 240V 206 C 98 2789 LABELS TERMINAL BLOCK TBS O OHO 480v 307 209 301 3778 D CONTROL BOX 130 225 N O COM N C N O COM N C 600 son 20 C 301 5779 CONTROL BOX 400 xi dus AUK 301 3579 DOOR ASSY 30 400 DOOR ASSY __ 400 301 3512 BRACKET CONTROL CENTER 400 406 0363 HINGE PiN ca a ee ee WASHER NYLON WIRING DIAGRAM 301 3524 PLATE STRIKER INSIDE VIEW OF CONTROL BOX 5 99 1269 NAMEPLATE CONTROL 406 0370 CURRENT TRANSFORMER 332 1356 MOUNTED HERE BUT 332 1024 SHOWN ON METER PANEL 352 1814 WHEN USED 352 1414 352 0050 TO LINE TO GEN A 9 NOTES 1 TRANSFER SW MECHANICALLY HELD LINE S DE 1787 8 187 6 7 7 CC CLOSING COIL Jex f J W ax J1 Z TC TRIP COIL CS CUTOUT SWITCH kl K2 IC INTERLOCK CONTACT 2 CONNECT LOAD TO RIGHT SIDE OF TRANSFER SWITCH ON 30 225 AMP CONNECT LOAD TO LEFT SIDE OF TRANSFER 2 10 SWITCH ON 400
73. SEE NOTE 4 NOTE 4 2 Tes 3 T04 l4 K3 SEE NOTE 17 e NL CONNECTIONS NOTE 12 Redistribution or publication of this document by any means is strictly prohibited SCHEMATIC DIAGRAM COM HI lt 2 H2 SEE HOTE 7 SEE 10 BNA SEE t4 Bo t CR2 p SEE NOTE 17 _ r r OO gu is SEE a SS 1 Il c 14 if FOR j REF 245 SONLY 6000 I2 lt SEE NOTE 1 71 3 NORMAL z EST 7 see NOTE 13 SEE NOTE E 121 6 STOP 214 24 4 NORMAL Qs a6 pA 85 9 SEE NOTE 12 SEE NOTE 9 4 t ae RMT 3 SEE IB 3 2 ob M ALL COMPONENTS SHOWN N DE ENERGIZED POSITION UNLESS OTHERWISE NOTED 2 2 WIRE START ON AT AT D CONNECT TO B GHD amp RMT 3 WIRE START E CONNECT TO B 1 2 8 3 PLUS ON DIESELS B TEST OR EXERCISE S2 SHOWN IN WITHOUT LOAD POSITION WITH LOAD PLANT STARTS AND TAKES OVER LOAD PLANT RUNS FOR DURATION OF TEST OR EXERCISE PERIOD PLUS ANY TIME DELAYS 8 2 WITHOUT LOAD PLANT STARTS AND RUNS FOR DURATION OF TEST OR EXERCISE PERIOD 9 THIS CONTACT SYMBOLIZES A SOLID STATE SWITCH WHICH CLOSES AFTER 0 1 SEC TO 1 SEC DELAY AND OPENS AFTER A MIN MIN DELAY
74. SES IN A 10 SEC TIME SAMPLE TIME DELAY i5 MIN 10 DIVISION OF ONAN CORPORATION Minneopalis Minnesota TEST FPROCEOURE fev RE TRANSFER XFR Redistribution or publication of this document by any means is strictly prohibited 539 0377 Tg 55 RELAY 307 1058 c ii FORM 1071 Power _ Generation 1 01 610 Mer um th phet mm tp doy tha ih gt a Oran atp p ght osa eaten fert uU gihgen WAS 2 gt 22 78 DELETED TEST CONNECTOR 4 55 1006 22 78 TERM 2 WAS TERM 21 was 22 Zs CDR u 22 78 pe NOTES 1 PLUG 12 V T D START STOP 300 1059 C INTO TEST FIXTURE 2 APPLY I2 TO 15 VDC 3 SET ALL SWITCHES IN OPEN 0 POSITIRN 4 MEASURE TIME DELAY 41 START CLOSE SWITCH SIDAND MEASURE TIME DELAY BETWEEN SWITCH CLOSURE AND RELAY K PICKUP TIME MEASURED AT 8 SEC ISEC 42 STOP OPEN SWITCH SIOAND MEASURE TIME DELAY BETWEEN THE SWITCH OPENING AND RELAY DROP OUT TIME MEASURED B SEC ISEC 5 FACTORY SET TIME DELAY WOE LAMPS THAT ARE COMPATABLE WITH 51 START BATTERY OR POWER SOURCE USED FOR TEST RESET SWITCHES 1 4 1 0 1 1 ON OFF ON ON AND MEASURE TIME DELAY TIME MUST EXCEED 5 MIN 9 2 STOP RESET SWITCHES 5 8 1 0 1 1 DN OFF ON ON AND WEASURE TIME DELAY TIME MUST EXCEED 5 MIN HER 539 0738 em rant wo orv evix MA
75. SS OTHERWISE SPECIFIED o esse in ad 5 Minneapolis Minnesota 1 E Generation 2 PLACE DECIMALS im Voor ns loth TEST EROCEDURE 7 227 72 pe 539 0 99 Redistribution or publication of this document by any means is strictly prohibited 539 0202 TEST CONNECTOR 332 2107 TERMINALS c 332 2108 A rg Power Generation OVERORANK Js S5 INHIBIT STAR _12V OR BC SUPPLY USE LAMPS THAT ARE COMPATABLE With BATTERY SOURCE U BED FOR TEST A NOTE 7 TIME WAS 150 SEC rJ 25505 DWG SAME No SIZE D ATEO 7 41 72 2 8 1416 5 28 77 WAS I271 0 4 WAS 332 1269 44 5 79 0 5 1 PLUG 2 3 HIRE CONVERTER 300608276 1 TEST FIXTURE 2 SET SELECTOR SWITCH OR COHVERTER IN NOAWAL POSITION PLACE 51 52 S3 AND CLOCK SWITCH OPEN POSITION 3 APPLY 12 15 VDC STOP LIGHT SHOUL 4 MEASURE MINIMUM DVERCRANK DELAY PDT R 7 MAX CCW 4 1 CLOSE CLOCK SWITCH CLOSE SWITCH 51 STOP LIGRT EQES GFF START LIGHT GOES OH AFTER TIME DELAY START LIGHT OFF QVERCRAHK LIGHT ON TIME SELAY HUST BE LESS THAN 5 SEC 4 2 OPEN SWITCH S1 RESET SWITCH ON CONVERTER ANB OPEN CLOCK SWITCH NOTE OBSEAYE
76. START STOP sos nszwtrk vo sTART STOP 191 SEC 18 SEC DELAY START DELAY OM STOP 5 xoo usmifEF C 1 TRANSFER METRANSFER 1 T ISEC 3015 SEC DM TRANSFER Lem To 30MIN ON RE TRANSFER 3000987 1 MODULE BLANK SPARE M D 500 0926 1 2 TOSWIRE CONVERTER LAT 10 300 0937 6 1 MODULE GLANK SPARE w Bocoretm 1 GATTERY VOLTAGE SENSORIAT D A E s mooorrhtic BATTERY VOLTAGE SEMSGRIAT C Anz 300 0937 8 2 MODULE BLANK SPARE 2131415 500 0937 8 3 MODULE BLANK SPARE 6 L posoreomeri 3 ovem sensor CNET ais 506 0937 8 MODULE BLANK SPARE MCOULE TD AITO 1300 0937 2 MODULE BLAHK SPARE Ai 13004625 PANEL ASSY SWiINGING Ae 00 2 CONTROL START SUPPRESSOR 2 Fi 32589 FusE 24uP 208 2409 8 2 1 TFUSE HOLOER 307 038 18 RELAY INTERPOSING LINE EV 4 5074068 1 RELAY INTENPOSIMG GEN 1507 41058 B RELAY RETRAHSFER 2v 307 058 RELAY OVER VOLTAGE LIMEU V 507 058 a RELAY STARF 42
77. TERIAL AME Onan mra lt DIVISION OF ONAN CORPORATION Minneapolis Minnetolg TEST PROCEDURE 12 ERES AT PROGRAM TIMER 539 057 Redistribution or publication of this document by any means is strictly prohibited AT S WITH CONTROL PANEL GROUPS 51 THROUGH 55 Find the problem below and proceed to the page indicated Then answer the questions in the chart on that page either YES or NO Refer to the number in the column and proceed io that step etc INDEX PROBLEM Automatic transfer switch fails to immediately connect toad to line when generator set is not running 70 Automatic transfer switch fails to connect load to generator set when set runs during test with load or during a normal power outage Automatic transfer switch fails to start generator set during a power outage Automatic switch fails to automatically retransfer load from generator set to line after normal power returns Generator set continues to run 8 eee until generator set stops after a power outage 76 Generator set starts during normal power service 77 Exerciser clock does not start generator set Overcrank lamp does not light on overcrank condition AT E only l rua Power 63 Redistribution or publication of this document Generation by any means is strictly prohibited A Automatic transfer switch fails to immediately connect
78. TIONS FOR CONTROL ACCESSORY PANEL Power Redistribution or publication of this document _ Generation 19 T a To by any means is strictly prohibited E 4 CONTROL ACCESSORY PANEL eo a BENE FLANGED EDGE OF HINGE PIN SPACER CABINET DOOR FIGURE 4 BOTTOM HINGE PIN FOR CONTROL ACCESSORY PANEL 7 Hold the flange edge of the control accessory panel s bottom hinge pin with a needle nose pliers just above nylon spacer and remove screw from pin with a screwdriver The pliers prevent the pin from turning when loosening the screw Figure 4 o WARNING When screw is removed control accessory panel is loose on bottom Have someone holding the pane during removal procedures to prevent personal injury 8 Carefully pull outward on bottom of control accessory panel until it clears cabinet 9 Lower control accessory panel from cabinet Top hinge pin will come out with control accessory panel 10 Remove the top hinge pin from control accessory panel and install on new panel if required 11 Lift up new control accessory panel into cabinet carefully engaging top hinge pin 42 Center the hole on the bottom control panel flange over hinge pin 13 Insert the screw in bottom hinge pin and tighten with screwdriver and pliers Install the terminal boards from new control 20 1 18 19 20 accessory panel on the wall of th
79. TOP on engine contro fortwo wire starting in AT cabinet for three wire starting Disconnect the starting batteries Remove AC line voltage from the automatic transfer switch WARNING Failure to remove AC power from the automatic transfer switch and to disable the generator set presents a serious shock hazard during this modification Remove the twist lock disconnect plug and con trol accessory panel Rewire the stepdown transformers T2 T3 T4 and TS using the wiring diagram furnished with the control accessory panel Change the wire lead connections on the right side facing panel rear of the terminal strip for the transformers See Figure 5 Rewire battery chargertransformer T1 sothe wire from F1 2 and 1 5 COM goto the appropriate connections on the transformer for the nominal voltage Figure 6 See the wiring diagram for the correct connections Close the control accessory panel Heconnect the twist lock disconnect plug Restore AC line voltage to the automatic transfer Switch Reconnect the starting batteries Redistribution or publication of this document by any means is strictly prohibited STEPDOWN TRANSFORMER T2 XXE TAP CONNECTIONS THRU 6 z Sete 2 STEPDOWN TRANSFORMER T3 Efil TAP CONNECTIONS 7 THRU 12 2 e j yt 5 d E 1 th ri 22 7 m 3 SENS 2 Ww SS en hw Tea WM REA
80. V T2 5 480 V T2 6 600 V AC INPUT LEADS FOR TRANSFORMERS TRANSFOHMEH LEADS FIGURE 14 CONNECTION OF VARIAC TO STEPDOWN TRANSFORMER Power Redistribution or publication of this document by any means is strictly prohibited Generation 30 E adi XP sos A the disconnect plug 32 Make the sensor settings See Undervoltage Sensor Settings near end of section Overvoltage Sensor Calibration 1 ei Open the cabinet door of the automatic transfer switch Move the operation selector switch to STOP on engine control for two wirestarting in cabinet for three wire starting Turn the DROP OUT DIFFERENTIAL knobs to minimum and the PICK UP VOLTAGE knobs to the clockwise limit maximum On the sensor to be calibrated turn PICK UP VOLTAGE knob very slowly counterclockwise until you hear relay K6 close This reading times the multiplying factor should equal the line voltage Check line voltage with a voltmeter divide by thefactor to seeif the reading is correct If it is proceed to Step 6 Otherwise proceed to Step 5 Setting Too Low a Turn the DROP OUT DIFFERENTIAL knob counterclockwise to minimum b Turn the PICK UP VOLTAGE knob ta the desired setting c Insert a smal screw driver through the CALIBRATE hole and turn counterclockwise very slowly until you hearrelay K6 pick up Setting Too High a Turn the PICK UP VOLTAGE knob to its clockwise lim
81. alibration 28 Overvoltage Sensor 31 Undervoltage Sensor 05 32 Overvoltage Sensor Settings 32 Pato ront ONA Geira 32 Battery Voltage Sensor Alarm 5 33 High Battery Voltage Alarm Setting 33 Low Battery Voltage Alarm Setting 33 Overcrank Time AT E 34 Frodramieg u sa ados Ic EROR 34 Time Delays Conirol Groups 10 15 and 20 25 usce oe RE 34 Time Delays Control Groups 51 55 Cr P ee 38 THANSPEH aeg ur vacio Bee prd EU 39 Transiter Switch DescHpI DEus ee da p m3 EROR ER ARDOR RUE EROR 39 CONTACTS e 39 T ranstet OWON CONS ri iaa d doc Rp EL ird A 39 Mechanical Lat
82. anism obstructed 20B Is rated voltage across closing coil 2 26B 21 21 Does transfer switch operate if normally closed 1 contacts are jumpered 22B 23B 228 Repair or replace normally closed K2 IC contacts 23B Is transfer switch mechanically held on generator side 28 26B rua Power 17 Redistribution or publication of this document ud Generation by any means is strictly prohibited Eig pp o Continued YES Does transfer switch operate if cutout switch K2 CS is jumpered 25B Repair or replace cutout switch K2 CS me Closing coil K1 CC is open circuited or switch mechanism is obstructed preventing transfer switch closure Fa Power 13 Redistribution or publication of this document d Generation by any means is strictly prohibited Automatic transfer switch fails to start generator set during a power outage AT C AND AT D Two Wire Start 1C Place automatic transfer switch selector switch 52 to TEST Does generator set start 2c Is selector switch on engine control in REMOTE position 3C Does generator set start run and stop with switch located on engine control Return switch to remote position 4C Jumper 1 to TB1 RMT Check to ensure that voltage from GND to TB1 RMT is equal to battery rated voltage Does engine crank 5C Check circuit from TB1 B through AT switch S2 1 2 to TB1 RMT for loose connecti
83. arks on the modules Turn the pick up voltage knobs to 90 or below Does generator set stop after time delay if applicable After test return knobs to original settings Recheck the normal line voltage and output voltage of transformer for voltage sensor modification for lower than normal readings Make sure voltage sensors are set for correct pick up voltage Is automatic transfer switch a 3 phase AT Is phase protection relay K6 energized and the contacts K8 3 5 closed and making good contact Replace phase protection relay K6 Does AT have a start time delay K7 Measure for rated AC voltage nominal 220 volts with 480 or 600 volt system from terminal K7 L1 to K7 L2 If present repair or replace start time delay relay K7 is start stop relay 7 energized and are contacts K7 1 5 open Replace start stop relay K7 Generation Redistribution or publication of this document by any means is strictly prohibited G Exerciser clock does not start generator set i YES 1G Does exerciser motor timer M1 operate 2G 15G 2G Is operation selector switch S2 at NORMAL 3G 3G Has overcrank condition occurred 4G 4G Does generator set have two wire starting 5G 6G 5G Are contacts M1 3 5 closed and making good contact to put battery voltage on TB1 RMT terminal during exerciser period See instructions for exercise clock adjustments 16G 6 Are contacts M1 4 5 open and M1 3 5
84. as a blank spare be sure to use the following procedure iP 2 8 Open the cabinet door Move operation selector switch to STOP on engine control for two wire starting in AT cabinet for three wire starting and disconnect starting battery Remove AC line voltage from the automatic transfer switch WARNING Be sure to remove AC line voltage from the automatic transfer switch and dis able the generator set Otherwise the automatic transfer switch presents a serious shock hazard Remove the twist lock disconnect plug and open control accessory panel Install keying 332 2114 for begin Spec C or 332 1276 for Spec A or B AT in the siot s of the printed circuit board receptacle as needed Figure 9 shows how a keying plug is inserted into ihe receptacle See a control accessory panel wiring diagram showing location of the keying plug s for that particular module Insert the new module in the control accessory panel Restore AC line voltage to the automatic transfer Switch Close the control accessory panel and reconnect the disconnect plug Power _ Generation 26 9 Move the operation selector switch to RMT on engine contro for two wire starting or NOR in cabinet for ihree wire starting whichever applies 10 Close cabinet door MAL S 00 6 NS NAN 7 4 5 gt G y amp Q
85. cabinet door I 10 MODULE TEST PROCEDURES The following drawings give test procedures for the individual modules Note on the drawings that test circuits are usually required you find a module defective or the correct calibration cannot be ob is operation selector switch and check operation of tained replace it Power 14 Generation Redistribution or publication of this document by any means is strictly prohibited cn cn 539 0161 22 POINT TEST B RECEPTACLE TERMINAL ONAN NO 332 2107 A NO 332 2108 A SEE NOTE 323 O760A R 323 0765 A SUCH A F 322 rid A 4 VARIAC O I40V INPUT ZOV 4 TO EXTERNAL VOLTMETER C126 ACCURACY OR BETTER TO EXTERNAL CIRCUIT SCHEMATIC DIAGRAM 12 TEST CIRCUIT ABTES 1 VAnIAC MUST BE SMALL SIZE WITH VERY SMOOTH CONTROL FOR FING ADJUSTMENT OF VOLTAGE IN RANGE OF 90 140 VOLTS ASSEMBLY TOLERANCES UNLESS OTHERWISE SPECIFIED OFC tm als l 2 acE FRACTIONS ANGLES the proprietor design infermarian thin pnt is td by tha Onor Divivon ion roseis de al this sight is nof exlanded 19 Power Generation t SET PICK UP CONTROL TO MARK BETWEEN 110 amp 120 5 REDUCE INPUT VOLTAGE SLOWLY TO VOLTS INCREASE PICK UP VOLTAGE SETTING TO 140 VOLTS INGREASE INPUT VOLTAGE LAMP OR BUZZER H Wu P ERIS var 89 16 70 o7
86. ch and Cutout Switch 40 TRANS TIU Sura uA EE RARE EIER ER go 40 THOBB LESHOOTING ENE aed RS au add 41 Index for AT s with Control Panel Groups 10 15 and 20 25 41 Index for AT s with Control Panel Groups 51 55 69 24 Power 1 Redistribution or publication of this document 2 C Generation by any means is strictly prohibited GENERAL INFORMATION ONAN SERVICE MANUAL This manual contains operation descriptions of typical AT transfer switches modifications ad justments troubleshooting procedures Whenever troubleshooting or planning a repair for an AT automatic transfer switch remember the generator set automatic transfer switch and commer cial power source are all interdependent Decide which is the source of the problem and then repair MODEL NUMBER SYSTEM Following is a typical model number with ex planations of the different parts Tipo rM 1 Series Identification 2 Transfer Switch Type U 3 pole transfer switch UL listed S 3 pole transfer switch Special or CSA approved N 4 pole 3 phase switched neutral using necessary and normal safety precautions Note WARNING on inside the front cover of this service manual which states that a qualified electrician or an authorized service representative must perform all service
87. control panel test transfer switch S1 2 1 and selector switch S2 2 3 to TB1 RMT for loose connections or open circuits 18C Move selector switch S2 on control accessory panel to WITH LOAD and test transfer switch S1 back to NORMAL Is DC voltage from TB1 GND to TB1 6 12 volts 20C 19C Check wire connections to voltage module 5 If OK replace module 5 Power 45 Redistribution or publication of this document e _ Generation by any means is strictly prohibited Continued 20 Jumper TB1 6 and J7 9 Does generator set start aliow for start time delay if used 21C Replace interposing relay K3 22C Is module 7 a start stop time delay module 23G Replace start stop time delay module 7 with a bypass plug or jumper J7 9 to J9 2 Does generator set start 240 Replace start stop time delay module 7 25C Is voltage from TB1 GND to J7 21 J7 22 for Spec A and B only about 12 volts DC 26C Replace start suppressor control A21 270 Begin Spec C Replace start relay K7 K7 contacts 4 7 do not close to connect TB1 B to TB1 RMT pi Power _ xdi Generation ta HMM RP M Aree YES NO 21C 22C 23C 25C 24C 25C 26C Redistribution or publication of this document by any means is strictly prohibited Automatic transfer switch fails to automatically retransfer load from generator set to line after normal power returns Generato
88. cts M1 4 5 open and contacts M1 3 5 close to put battery voltage on TB1 RMT terminal during exercise period See instructions for exercise clock adjustments 4G 4G Replace the microswitch on the exerciser clock or replace exerciser clock 5G Is fuse F1 in control panel blown 6G Replace fuse Ft s Battery Charger Malfunctions YES NO Does battery charger fail to charge Charge ammeter shows zero current and battery discharges Does battery charger charge at high rate and cause battery to lose electrolyte look for bubbling Does charger supply current but battery fails to supply sufficient cranking power Lower charger fioat voltage a small amount Measure specific gravity once a week and readiust float voltage until charger will hold recommended specific gravity without overcharging Increase float voltage again if specific gravity drops below recommended value Check battery under load to see if it might have a dead cell Check specific gravity of battery electrolyte and increase float voltage a small amount check specific gravity once per week and reset float voltage until charger will hold recommended specific gravity Check fuse F1 15 fuse OK Does primary of transformer T1 have rated input on correct terminals to produce approximately 20 volts AC on T1 X1 X2 or approximately 40 volts on T1 X1 X3 Remove module 6 and measure AC voltage at J6 15 21 Is this approximately
89. e variac Connect the variac to a 120 volt AC source Reconnect the disconnect piug Rear of control accessory panel and transfer switch are energized Do not touch due to serious shock hazard Turn all the undervoltage sensor knobs to minimum Adjust the Multi Tester or variac to give a 120 volt output for the undervoltage sensor module Turn the PICK UP VOLTAGE knob on the sensor to be calibrated to its clockwise limit Turn the knob very slowly counterclockwise until you hear relay K3 pick up The knob should indicate 120 volts If not proceed to Step 20 If it does read 120 volts proceed to Step 21 Setting Too Low a Tum the PICK UP VOLTAGE knob to its clockwise limit then counterclockwise to desired setting b Insert a small screwdriver through the CALIBRATE hole and turn counterclockwise very slowly until you hear relay K3 pick up Setting Too High a Tum the PICK UP VOLTAGE knob to its clockwise limit b Inserta small screwdriver through the CALIBRATE hole and turn to its clockwise limit c Turn the CALIBRATE adjustment counterclockwise very VARIAC REMOVE TRANSFORMER LEAD POSITE TRANSFORMER VOLTAGE INPUT WIRE AND TAPE 208 V INPUT SHOWN SEE TEXT FOR EXCEPTIONS SHOWN FOR 120 V VAHIAC WITH OUT PUT CONNECTED TO T2 1 COM AND T2 2 120 V TRANSFORMER LEADS FOR UNDERVOLTAGE SENSOR 1 OR OVER VOLTAGE SENSOR 13 21 22 23 24 25 26 27 28 29
90. e cabinet using 6 32 screws TB2 mounts just above TB1 remote terminal block TB9 just above TB2 and TB6 in the upper right side Connect loose wire leads to terminal blocks as marked If an area protection circuit or remote test switch is used remove the jumper between terminals T81 4 and 5 and connectthe wire leads from the equipment If the AC voltage of the new control accessory panel is different see Changing Control Accessory Panel AC Voltage lf the DC system voltage and number wire start is different on the new control panel see Changing Control Accessory Panel DC System Voltage and or Three to Two Wire Start Conversion 12 Volts or Two to Three Wire Start Conversion 12 Volts For external alarms or signal circuits of the battery voltage sensors connect lead wires to 1B2 These contacts are rated 2 amperes for 12 volts DC or 120 volts AC Ciose the control accessory panel and reconnect the twist lock disconnect plug Power 2 Redistribution or publication of this document Generation by any means is strictly prohibited 21 22 23 24 Restore AC line voltage to the automatic transfer switch Reconnect the starting batteries Move operation selector switch to RMT on engine control for two wire starting or NOR MAL in cabinet for three wire starting whichever applies Close the cabinet door Panel Groups 51 Through 55 The new control accessory panel installed
91. el outward Remove LO BAT VOLT lamps DS13 and HI BAT VOLT lamp DS14 from the meter lamp panel and replace with 322 0114 and 322 0115 lamps respectively Close the meter lamp pane and secure the top and bottom with the two screws 400 ampere AT only Close the left cabinet door Secure the door to the cabinet center support with the screw removed in Step 12 TRANSFORMER TI d FIGURE 7 BATTERY CHARGER TRANSFORMER DC CONNECTIONS Generation Power 23 Redistribution or publication of this document by any means is strictly prohibited I 1 US B151 FA 1 R REAR OF CONTROL ACCESSORY PANEL opum ee 7 RI 3 FIGURE 8 CHANGING RESISTOR R1 TAP SETTING 18 Close the control accessory panel and reconnect the twist lock disconnect plug If starting is changed from two to three wire starting proceed to that modification described in this section 19 Connect a 12 volt battery and restore AC line voltage to the automatic transfer switch 20 Move the operation selector switch to RMT on engine control for two wire starting or NOR MAL in cabinet for three wire starting 4 Hemove AC line voitage from the automatic transfer switch ARNING Failure to remove AC power from ihe automatic transfer switch and to disable the generator set presents a serious shock hazard during this
92. er lamp panel from Step 7 2 Move operation selector switch to STOP on 14 400 ampere AT only Shut the left cabinet door engine control for two wire starting in cabinet for Secure the door to the cabinet s center support three wire starting with the one screw removed in Step 6 Remove AC line voltage from the automatic 15 Close the control accessory panel and reconnect transfer switch the twist lock disconnect plug Disconnect the starting batteries 16 Restore AC line voltage to the automatic transfer Failure to remove AC power from the switch automatic transfer switch and to disable 17 Move the operation selector switch to RMT on the generator set presents a serious shock hazard during this engine control for two wire starting or NOR t for three wire starting Remove the twist lock disconnect plug and open the control accessory panel Remove external wires from TB1 TB2 TB6 and 19 Close cabinet door TB9 if all present then remove these terminal blocks from mounting See Figure 3 AX 2 TERMINAL aan BOARD TB6 Er CES CONTROL ACCESSORY ics 28 PANEL av tT O H d TERMINAL BOARD TB9 AUXILIARY CONTACTS TERMINAL BOARD TB IN VOLTAGE SENSORS 1 TERMINAL BOARD TB REMOTE START CONTROL FIGURE 3 TERMINAL BOARD CONNEC
93. erminals A and B Make sure single phase voltage matches transfer switch voltage 9 Control accessory groups 10 15 and 20 25 For control accessory panels with plug in modules remove undervoltage sensors 2 and 3 if equipped Insert 300 0927 bypass plug modules into the module openings 2 and 3 Power Generation Incorrect voltage may damage transfer switch different generator set is used with a different voltage starting system see Changing Control Accessory Panel DC System Voltage Control accessory groups 51 through 55 When changing phase of an AT with oneof these control accessory panels replace the panel with one matching the single phase voltage See Changing Control Accessory Panel 10 Remove the one screw on top and one screw bottom from inside the meter lamp panel flange 11 Swing meter lamp panel outward 12 If the meter lamp panel is three phase only remove the panel as described under Changing Meter Lamp Panel If the meter lamp panel is a single or single and three phase panel rewire the connections on transformers T11 and 112 if equipped See Figure 1 a For 120 volts reconnect lead from TB7 10 to T11 2 and reconnect lead from TB7 8 to T12 8 b For 240 volts reconnect lead from TB7 10 to T11 4 and reconnect lead from TB7 8 to T12 10 STEPDOWN TRANSFORMER T I COM TH 2 11 4 12 7 COM 2 8 T12 10 STEPDOWN TRANS FORMER 2 3
94. etween TB1 4 and 5 relay K3 is energized as described under Restoration of Normal Line Redistribution or publication of this document by any means is strictly prohibited RESTORATION OF NORMAL LINE When the normal line voltage returns it completes a circuit from normal line B drawing 626 0106 to receptacle terminal J1 Y plug terminal P1 Y drawing 626 0075 relay K8 plug terminal P1 Z J1 Z draw ing 626 0106 and to normal line C Helay K6 energizes and closes contacts K6 3 5 drawing 626 0075 to complete a circuit from normal line A drawing 626 0106 to receptacle terminal J1 X plug terminal P1 X drawing 626 0075 K10 retransfer time delay motor contacts K10 TDO contacts K6 3 5 TB1 4 and 5 test transfer switch S1 plug terminal P1 Y receptacleterminal J1 Y drawing 626 0106 and to line B Time delay K10 energizes drawing 626 0075 and after the time delay period closes contacts K10 7 8 to complete the circuit to energize relay K3 and to energize stop time delay K9 through K9 TDO contacts Contacts K3 5 6 close and contacts K3 1 3 open Open contacts 1 3 break the circuit to TB6 8 and to TB7 8 drawing 626 0106 to de energize the K2 closing coil Power from normal line B drawing 626 0106 completes a circuit through receptacle terminal J1 Y plug terminal P1 Y drawing 626 0075 closed contacts K3 5 6 disconnect plug terminal P1 W receptacle terminal J1 W drawing 626 0106 cl
95. following ADJUSTING SCREW ON LATCHING LEVER 27 lt LATCHING LEVER LOCKING this procedure 1 Loosen the locking screws which secure the latching brackets 2 Adjust the bracket for 1 16 inch 1 6 mm clearance between the contact control rod the latching lever when the main coil armature is fully seated Figure 22 The 200 225 and 400 ampere transfer switches have a Slightly different appearing tatching mechanism but have the same operation sequence and use the same adjustments Cutout Switch Adjustments Adjust the coil cutout switch by following this procedure 1 Align the microswitch actuating arm and the adjusting screw on the latching lever 2 Set the adjusting screw so the microswitch opens _ just as the latching lever engages the contact operating rod 3 Operate the transfer switch severaltimes to check the microswitch adjustment 4 Adjust as required and seal the adjustment with paint TRANSFER SWITCH HUM Hum of mechanically held transfer switches is caus ed either by incorrect adjustment of the coil cutout switch or because of dirt between the armature sealing faces of the switch hum is duetothe cutout switch adjustment see MECHANICAL LATCH AND CUTOUT SWITCH in this section If hum is due to dirt between the armature sealing faces clean them with Dowclene EC Chlorothene Nu similar elec trical cleaning material Use medium fine grade eme
96. he load through the closed K2 contacts lines A B and C shown in the schematic diagram 626 0106 The closing coil CC of transfer switch K1 is originally energized from terminal A on the line side through the closing coil CC normally closed K1 contact CS normally closed K2 contact IC terminal W of receptacle J1 Terminal J1 W connects to terminal W of disconnect plug P1 drawing 626 0445 which connects to normally closed K4 contact 3 9 and back to Y terminal of disconnect plug P1 P1 Y connects to terminal Y of receptacle J1 drawing 626 0106 J1 Y connects to line B on the line side of transfer switch K1 Once mechanically held transfer switch on line side is picked up by the commercial line it is mechanically held in that position until the trip coil is energized The normal lamp DS11 on the meter lamp panel lights to indicate the presence of normal line power A circuit is completed from normal line A through TB7 11 drawing 626 0164 through transformer T11 primary windings 10 drawing 626 0106 con tacts K2 IC receptacle J1 terminal W disconnect plug P1 terminal W drawing 626 0445 contacts K4 3 9 disconnect plug P1 terminal Y receptacle J1 terminal Y drawing 626 0106 to normal line B The primary of transformer T11 drawing 626 0164 in duces a voltage in the secondary windingsto light the NORMAL lamp DS11 Battery Charging The transfer switch line side K1 terminals A and B feed J1 receptacle term
97. he remote RMT terminal signaling the generator set to stop AUXILIARY CONTACTS ON LINE SIDE AND GENERATOR SIDE Small switches mounted on the transfer switch actuated by the moving armature provide dry con tacts to indicate transfer switch position Diagram 626 0106 shows the K1 auxiliary contacts 55 connec ting to TB9 terminals 1 2 and 3 The normally open contact connects to terminals 1 and 2 and the normally closed contact connects to terminals 2 and 3 The auxiliary contacts 56 have anormally open contact connecting to terminal block TB9 terminals 4 and 5 and a normally closed contact connecting to terminals 5 and 6 EXERCISER CLOCK The exerciser clock starts and stopsthe generator set automatically for periodic test operations Drawing 626 0445 shows the exerciser clock M1 motor circuit connected to stepdown transformer T1 terminals X4 and X5 Transformer T1 primary connects to the line side of the transfer switch through disconnect plug terminals X and Y The exerciser clock cam operated switch contacts M 1 3 4 and 5 connect to test transfer switch S1 and selector switch S2 The 1 switch contacts are shown in the normal position with the contacts 3 5 open and contacts 4 5 closed After the operator selects the mode theexerciser clock automatically exercises the generator set Exercise Without Load With switch S2 in the WITHOUT LOAD position the exerciser ciock closes contact M1 3 5 to complete the c
98. his document by any means is strictly prohibited UT LA WAS DIFFERENT TYPE LIGHT 4 B WAS 7S SECONDS OR 4 4 m WAS 332 1271 D 5 332 1266 NOTES 1 PLUG TB PREHEAT 300 1072 INTO TEST FIXTURE 2 3 INHIBIT 2 APPLY 12 15VBD NO LIGHTS SHOULD COME 09 3 SET TIME DELAY 51 2 3 INHIBIT AND HEATER LIGHT SHOULD COME DN SET ADJ POT SO INHIBIT LIGHT GOES OFF GO 5 SECONDS AFTER 51 IS CLOSED 4 AFTER INHIBIT LIGHT GOES OFF CLOSE 82 HEATER LIGHT GDES INHISIT LIGHT STAYS DFF 8 OPEN 52 HEATER LIGHT TURNS ON INHIBIT LIGHT STAYS OFF 6 CLOSE 3 HEATER LIGHT GOES OFF INHIBIT STAYS OFF 7 OPEN 3 HEATER LIGHT TURNS ON INHIBIT STAYS OFF 8 CLOSE 4 HEATER LIGHT GOES OFF INHIBIT STAYS OFF 9 OPEN 54 HEATER LIGHT AND LIGHT TURN ON 10 OPEN S1 BOTH LIGHTS 60 OFF USE LIGHTS THAT ARE COMPATABLE WITH BATTERY OR POWER SOURCE USED FOR TEST TEST CONNECTOR c 227 2107 A TERMINALS 32 2108 539 0238 9 DESCRIPTION OR MATERIAL oy pri DIVISION OF ONAN CORPORATION TOLERANCES UNLESS OTHERWISE 5 Ongn Minneapolis Minnesota on TEST PROCEDURE 12V i TD PREHEAT tophnsrary dasiga infarmation on primi it W p a are 539 0241 FORM rua Power Redistribution or publication of this document MUN Generation byany means
99. ibit ground circuit from module 9 terminal 14 Module 9 connects battery ground to 1 3 start circuit and remove ground from TB1 2 stop circuit The generator set starts PUSH TO RETRANSFER AND SELECTOR SWITCHES some automatic transfer switch installations require that the generator set continueto supply poweruntil a retransfer signalis manually initiated after restoration of normal power Some installations also require a selector switch for choice of automatic retransfer or manually initiated retransfer through a push to retransfer switch Drawing 626 0445 shows both the selector switch S3 and push to retransfer switch S4 Manual Retransfer With 53 selector switch in MANUAL position relays drop out on a voltage dip or a commercial power outage If the normal line restores voltage before the generator set can build up voltage normal ly closed contacts K4 2 8 will re energize relay K3to keep the load on the line If normal line power stays off the voltage sensor module 4 energizes relay K4 through bypass module 8 contacts 12 21 Relay contacts K4 2 8 open and contacts K5 4 7 remain open to prevent K3 from picking up when the undervoltage sensor modules 1 2and3ciosethe circuiton normal power restoration To initiate a retransfer when line power returns the operator must push retransfer switch S4 bypassing contacts K5 6 9 to energize relay K5 through the voltage sensors Contacts K5 6 9 close
100. ic transfer switch have NORMAL and EMERGENCY indicating lamps 4A is the green NORMAL lamp lit 5A Are contacts K1 CS closed to connect rated voltage across closing coil K1 CC 7A Repair or replace K1 CS contacts Is closing coil K1 CC open circuited or is there an obstruction preventing transfer switch from closing Are relay contacts K4 3 9 contacts K4 3 7 for control groups 20 25 closed and making good contact 11A Clean K4 contacts Does this correct problem Replace relay K4 dicm Does AT have programmed transition time delay assembly located in rear of standard cabinet below transfer switch 12A Does transfer switch operate if terminal TB11 1 is jumpered to TB11 2 13A Repair or replace time delay K11 Is transfer switch mechanically held on generator side 15A Are generator side main contacts of transfer switch open 19A Jumper normally open K2 interlock contacts in series with K2 trip coil Does transfer switch operate 2 Repair or replace normally open K2 interlock contacts a Is K2 trip coil open circuited or is trip coil mechanism obstructed Is rated voltage across closing coil K1 CC 23A Does transfer switch operate if normally 619568 K2 1C contacts are jumpered 21 Repair or replace normally closed 2 1 contacts Repair or replace cutout switch K1 Cs Closing coil K1 CC is open circuited or switch mechanism is obstructed preventing transfer
101. ictly prohibited 0926 remove and replace with a blank spare 300 0937 module 12 If module 10 is a 12 volt battery voltage sensor number 300 0796 remove and replace it with a 24 volt number 300 0797 sensor module 400 ampere AT only Remove the one screw from inside center support for left cabinet door and Open door 13 14 Remove one screw on top and one screw on bottom from inside meter lamp panel flange Swing the meter lamp panel outward Remove LO BAT VOLT lamp DS13 and HI BAT VOLT lamp DS 14 from the meter lamp panel and replace with 322 0126 and 322 0127 lamps respectively Close the meter lamp panel and secure the top and bottom with the two screws 400 ampere AT only Close the left cabinet door Secure the door to the cabinet center support with the one screw removed in Step 13 Close the control accessory panel and reconnect the twist lock disconnect plug 15 16 17 18 19 If starting is changed from three to two wire starting proceed to that modification in this section 20 Connect a 24 volt battery and restore AC line voltage to the automatic transfer switch Move the operation selector switch to RMT on engine control for two wire starting or NOR MAL in cabinet for three wire starting whichever applies Close the cabinet door 2T 22 TWO TO THREE WIRE START CONVERSION 12 VOLTS This procedure applies only to control accessory panels in gro
102. in left hand thread in the inside row of holes on the large dial for the time of day you want the generatorsetto start See Figure 11 14 15 16 TURN LARGE DIAL CLOCKWISE ONLY TURN SPOKED WHEEL COUNTERCLOCKWISE EXERCISE CLOCK SET TO START GENERATOR SET AT 98 A M EACH FRIDAY AND STOP IT AT 10 A M NOTE Trip pins are left hand thread FIGURE 11 EXERCISER CLOCK 4 Placea trip pin in the outside row of holes on the large dial to stop the generator set Onan recommends settings which operate the generator set for at least 30 minutes each week Exercising for one long period is better than several short periods 5 Install a trip pin in the small spoked wheel for every day no exercise is desired 6 Rotate the large dial clockwise until the correct time is correctly aligned with the time pointer 7 Align the small spoked wheel with the correct day at its pointer Sixteen trip pins are supplied with the clock Store unused pins on the time pointer bracket 8 Move the operation selector switch to RMT on engine control for two wire starting or NOR Power KNOB FOR DROP OUT DIFFERENTIAL 5 TO 20 MAL in cabinet for three wire starting whichever applies 9 Close the cabinet door AC VOLTAGE SENSORS Voltage sensors can be used for either undervoltage or overvoltage sensing on line or generator power supplies Range of the settings is from 90to 140 volts for a nominal 120 volt s
103. inals X and Y drawing 626 0106 and P1 plug terminals X and Y drawing 626 0445 to energize transformer T1 through fuse F1 Transformer T1 has three secondary terminals X1 X2 and X3 Terminals X1 and X2 supply approximately 20 volts output for 12 volt battery charging Terminals X1 and supply approximately 40 volts output for 24 volt battery charging For 12 volt battery charging transformer terminal 7 1 X2 connects to resistor R1 2 Resistor terminal R1 1 connects to terminal 21 of battery charger plug in module 6 Transformer terminal T1 X1 connects to terminal 15 of battery charger plug in module 6 The battery charger module rectifies and regulates the DC output voltage to float charge the cranking battery Positive output terminal 2 on module 6 supplies charging current through TB6 2 drawing 626 0106 TB7 2 drawing 626 0164 through the ammeter M11 TB7 1 drawing 626 0106 TB6 1 drawing 626 0445 tto the B terminal on TB1 which connects to the rua Power zz Generation positive terminal of the battery Terminal 4 of plug in module 6 connects to the ground terminal which in turn connects to the negative terminal of the battery This battery charging module 6 has a rated output of 2 amperes maximum and is voltage regulated to float the battery continuously without damage to the battery POWER OUTAGE When a power outage occurs commercial power source primary voltage to
104. ircuit from through switch contacts 51 2 3 M1 3 5 S2 2 3 to the remote RMT terminal The generator set starts and runs as previously described under Test Without Load until the exerciser clock contacts M1 3 5 open at the end of the exercise period Exercise With Load With selector switch S2 in the WITH LOAD position exerciser clock contacts M1 4 5 open the circuit to remove battery positive from line interposing relay K3 Relay K3 drops out the same as it doesifthereisa power outage and the generator set starts and runs as long as the exerciser clock contact remains open PREHEAT TIME DELAY The preheat time delay is optional on AT E automatic transfer switches It provides time foroperation of the diese engine glow plugs before remote signal for engine cranking Relay K7 is energized by receiving battery positive through start stop time delay module 7 the start Redistribution or publication of this document by any means is strictly prohibited suppressor control 21 voltage module 5 16 18 and from TB1 B drawing 626 0445 Contacts K7 4 7 close to connect battery positive to TB1 RMT andthe 2 to 3 wire converter module 9 Module 9 connects ground to preheat time delay module 16 terminal 5 Module 16 grounds TB1 H to complete the preheat circuit and grounds terminal 14 of module 9 to inhibit cranking during the preheat circuit period When the preheat time delay has ended module 16 removes the inh
105. ired Overvoltage Sensor Settings pick up and drop out voltages Use the following steps for setting overvoltage sen 25 Rather than reconnecting the voltmeter variac or sors Your settings however might vary considerably Multi Tester for the other overvoltage sensors if from the example shown due to your particular more than one pull out the already calibrated application requirements Use settings which give module and replace it with one of the other load protection and yet will avoid nuisance ad overvoltage sensors Then perform the calibra transfers tion procedures in this position 26 After calibration is complete remove the dis plug 1 Open the cabinet door 27 Disconnect the Multi Tester or variac and 2 Move the operation selector switch to STOP on voltmeter engine control for two wire starting with AT C or 28 Reconnect the wire leads removed and install the AT D control or in cabinet for three wire starting plastic cover over the terminals with AT E control 29 Close the control accessory panel and reconnect 3 Turn the PICK UP VOLTAGE knob to the desired the disconnect plug pick up voltage voltage at which load is 30 Make the sensor settings See Overvoltage Sen transferred from the normal power source to the sor Settings Undervoltage Sensor Settings Use the following steps for setting undervoltage sensors Your settings however might vary con siderably from the example shown due to your
106. it b Insert a small screwdriver through the CALIBRATE hole and turn to its clockwise limit c Turn the PICK UP VOLTAGE knob to the desired setting d Turn the CALIBRATE adjustment counterclockwise very slowly until you hearrelay K6 pick up Repeat Steps 3 through 5 for each overvoltage sensor If these calibrations are satisfactory for your application make the sensor settings See Overvoltage Sensor Settings near end of sec tion Fora more accurate calibration and calibration of the DROP OUT DIFFERENTIAL knob use the Onan Muliti Tester or a variac and use the follow ing procedure Remove the twist lock disconnect plug and open the control accessory panel On the back side and top left of the control accessory panel remove the white plastic cover which coversthetransformerterminais for T2 and TS Figure 13 In order to check voltage sensor calibrations you must vary the input voltage to the respective transformer The following procedure isolates transformer T2 from the normal line connection of the control and connects it to an independent power source 10 Remove the transformer leads from T2 1 and 2 2 120 V from left side of the terminal Power Generation 31 T3 Tes 13 14 15 16 76 19 20 strip and connect them to the output leads of a 120 volt variac 240 volt variac would require removal of transformer leads from T2 1 and T2 4 and connecting va
107. k or replace exerciser clock 15 Does have a start time delay relay K7 16C i7C 16C Has time delay K7 completed its delay 17C 17 Does generator set start if terminal K7 1 is jumpered to K7 5 18C 18C Replace relay K7 D Automatic transfer switch fails to automatically retransfer load IN from generator set to line after normal power retums Generator set continues to run NO 1D Is control panel disconnect plug inserted completely into receptacle 2D 2D Is test transfer switch S1 in closed NORMAL position 3D 3D Is rated AC voltage present at transfer switch line terminals 4D 4D Does automatic transfer switch have area protection equipment or remote test switch connected to terminals TB1 4 and 1 5 5D 7D 5D Jumper terminals TB1 4 to TB1 5 Does automatic transfer switch retransfer load to line at end of retransfer time delay if used 6D 7D 6D Check area protection equipment or remote test switch for malfunction circuit must be closed for retransfer 7D Is automatic transfer switch a 3 phase AT 8D 10D 8D Is rated AC voltage nominal 220 with 480 600 system present between terminals K10 6 10 8 10D 9D 9D Replace phase protection relay K6 SEN 10D Does AT have a retransfer time delay reiay K10 11D 183A 11D Has motor timer completed time delay period Time delay expired if AC voltage is present between terminals K10 6 K10
108. le if required 14 Close control accessory panel and connect the disconnect plug 15 Move the operation selector switch to RMT two wire starting engine control or NORMAL three wire starting in cabinet whichever applies 16 Close cabinet door Start Stop Bypass Plug Module Use this bypass plug module in place of the start stop time delay module in position 7 of the control accessory panel Use a 300 1648 bypass plug module for begin Spec C automatic transfer switches a 300 1177 bypass plug module for Spec A and Spec B automatic transfer switches You do not have to remove the keying plugs from the printed circuit board receptacle when using these bypass plug modules 1 Open cabinet door of automatic transfer switch 2 Position the operation selector switch at STOP on engine control for two wire starting or on automatictransferswitch forthree wire starting 3 Remove start stop time delay module 7 Insert the bypass plug module into position 7 5 Reposition the operation selector switch and check operation of the automatic transfer switch 6 Move the operation selector switch to STOP after the test is finished 7 Remove the start stop bypass plug module 8 Reinstall module from Step 3 or install new module if required 9 Move the operation selector switch to RMT two wire starting on engine control or NORMAL three wire starting in cabinet whichever applies Close
109. m ue TOLERANCES UNLESS OTHERWISE SPECIFIED FRACTIONS ANGLES 5 HOLES 006 002 DECIMALS 2 PLACE I PLACE Tha ptoprialgoy design Informalion pn this print owned by th Onon Division of Onan Conv eyonte of Ihip eight ja nol gmiendad to others INDEM SEA Tt Power Generation BATTERY OR POWER SOURCE USED FOR TEST _ a ADDED TEST LAMPS 7 8 72 6 1267 Aa CFI9 27 73 C ADDED NOTE NEG l2 nlgs COR amp 21 78 D juPDATED TEST BOAKD HOOK UP K c R5 6 21 78 NOTES 1 PLUG 24 Y T D START STOP 3006922 INTO TEST FIXTURE 2 APPLY 24 TO 30 VDC 3 TURN BOTH START AND STOP AD TO MINIMUM COUNTERCLOCKWISE POSITION 4 MEASURE MINIMUM BELAY 4 1 START CLOSE SWITCH St MEASURE TIME DELAY BETWEEN SWITCH CLOSURE AND RELAY PICKUP TIME MUST BE LESS THAN 0 5 SECOND 4 2 STOP OPEN SWITCH 1 AND HEASURE TIME DELAY BETWEEN THE SWITCH OPENING AND RELAY DROP OUT TIME MUST BE LESS THAN 0 5 MINUTES 5 FACTORY SET TIME BELAY 5 1 START TURN START ADJ CLOCKWISE CLOSE SWITCH S1 AND MEASURE DELAY TIME MUST 15 SECONDS ADJUST FOR 2 5 40 5 SECONDS DELAY 5 2 STOP TURN STDP ADJ CLOCKWISE OPEN SWITCH 51 AND MEASURE TIME DELAY TIME HUST EXCEED 5 MINUTES ADJUST FOR 5 50 5 MINUTES c HOLDING CURRENT REDUCE VOLTAGE To V2 RATING CRI4 SHALL STAY iM CONDUCTION No
110. mal test switch with load without load selector switch disconnect plug P Plug in module package available area protection terminals overcrank lamp on AT E only and engine start run signal W Wire in package available GROUPS 51 THROUGH 55 RELAY TYPE CONTROL GROUPS ACCESSORY 51 52 53 54 c standard Start Time Delay Transfer Time Delay Me Stop Time Delay Exerciser Ciock Preheat Time Delay AT E Only Undervoltage Sensor line Undervoltage Sensor gen Overvoltage Sensor line 2 515 lx Overvoltage Sensor Battery Charger 2 Amp SCR Float Battery Charger 50 to 300 ma Trickle rr Supplied Standard Includes voltage sensing relays normal test switch disconnect plug area protection terminals W Wire in package available engine Start run contacts cranking limiter overcrank lamp and manual reset AT E only 8 Meter Lamp Combination GROUP 01 02 03 o4 05 os 07 09 10 12 13 14 15 16 17 Charge Ammeter x Normal Emergency Lamps Battery Voltage Lamps AC voltmeter X Frequency Meter X Supplied standard ACCESSORY 18 a a E 9 Specification Letter Advances with production modification Power 3 Redistribution or publication of this document Generation by any means is strictly prohibited OPERATION DESCRIPT
111. me meter M12 2 Emergency lamp 0512 drawing 626 0164 lights to indicate generator power is available Generator line A drawing 626 0106 supplies power through 6 TB6 6 drawing 626 0445 contacts K4 4 7 K3 2 Redistribution or publication of this document by any means is strictly prohibited 8 B6 8 drawing 626 0106 TB7 8 drawing 626 0164 through transformer T12 primary windings back through TB7 12 drawing 626 0106 through K1 IC to generator line B The primary of T12 drawing 626 0164 induces a voltage in the secon dary windings to light the EMERGENCY lamp 0512 on the meter lamp panel Generator output to transfer switch K2 terminals A and B drawing 626 0106 through TB7 6 and 7 drawing 626 0445 energizes the primary winding of transformer Transformerterminais X1 and X2 feed a nominal 40 volts into voltage sensor module 4 terminals 12 and 15 When output voltage exceeds the set point of the module module 4 contacts 8 10 close the circuit through generator interposing relay K4 to terminal 12 of transfer retransfer time delay module 8 Battery positive voltage feeds through terminal 16 and 18 of voltage regulator module 5 to terminal 21 of module 8 Module 8 delays closing of solid state switch 8 12 21 to energize relay K4 Helay K4 completes a circuit from generator line A through TB7 6 drawing 626 0106 TB6 6 drawing 626 0445 is closed through K4 4 and 7 K3 2 and 8 TB6
112. must match AC system voltage and start control 2 or 3 wire of panel removed 1 2 10 11 12 13 14 Open automatic transfer switch cabinet door Move the operation selector switch to STOP on engine control for two wire starting in AT cabinet for three wire starting Disconnect the starting batteries Remove AC voltage from the automatic transfer switch Failure to remove AC power from the WARNING WARNING automatic transfer switch and to disable the generator set presents a serious shock hazard during this modification Remove the twist lock disconnect plug and open control accessory panel then remove the terminal blocks from mounting see Figure 3 Hold the flange edge of the control accessory panels bottom hinge pin with a needle nose pliers just above nylon spacer and remove screw from pin with a screwdriver The pliers prevent the pin from turning when loosening the screw Figure 4 WARNING When screw Is removed control accessory panel is loose on bottom Have someone holding the panel during removal procedures lo prevent personal injury Carefully pull outward on bottom of control accessory panel until it clears cabinet Lower control accessory panel from cabinet Top hinge pin will come out with contro accessory panel Remove the top hinge pin from control panel and install on new panel if required Lift up new control panel into cabinet
113. n Then movethetesttransfer switch S1 from NORMAL position to TEST position Relay contacts K3 1 7 close to energize start stop time delay module 7 After the time delay ends module 7 closes contacts 2 21 to energize relay K7 Contacts K7 4 7 close to connect to the remote terminal TB1 HMT which initiates engine cranking As the generator set comes up to speed generator output voltage to transfer switch generator terminals A and B drawing 626 0106 through TB6 6 and 7 drawing 626 0445 energizes the primary of step down transformer T3 Transformer T3 terminals X1 and X2 feed a nominal 40 volts into generator voltage sensor moduie 4 terminals 12 and 15 When this output voltage exceeds the set point of the voltage sensor module 4 module 4 contacts 8 10 close the circuit through generator interposing relay K4 coil to terminal 12 of transfer retransfer time delay module 8 Battery positive voltage feeds through terminals 16 and 18 of the voltage regulator module 5 to module 8 terminal 21 Module 8delays closing of the solid state switch 8 12 21 to energize relay K4 Once the time delay has completed contacts K4 4 7 close the circuit through K3 2 8 TB6 8 drawing 626 0106 TB7 8 K1 contact now held closed by the mechanically held mechanism to energize trip coil K1 TC The circuit to relay K2 is also completed through the K1 IC transfer switch contacts The transfer switch operates to open the K1 contacts removing the
114. nd turn counterclockwise very slowly until you hear relay K6 pick up Setting Too High a Turn the PICK UP VOLTAGE knob to its clockwise limit b Insert a small screwdriver through the CALIBRATE hole and turn to its clockwise limit c Turn the PICK UP VOLTAGE knob to the desired setting d Turn the CALIBRATE adjustment counterclockwise very slowly until you hear relay K6 pick up Turn the sensor module PICK UP VOLTAGE Knob to 132 volts relay K6 should drop out Increase the AC output voltage from the Multi Tester or variac until relay K6 picks up at ap proximately 132 volts Decrease the Multi Tester variac output voltage to check DROP OUT DIFFERENTIAL With the knob set at 5 percent relay should drop out at approximately 95 percent of 132 volts 125 to 126 volts If not use a small screwdriverto loosen the knob and reposition so it indicates 5 percent with drop out voltage of 125 to 126 voits Redistribution or publication of this document by any means is strictly prohibited 21 Set the PICK UP VOLTAGE and DROP OUT cabinet to NORMAL for three wire starting DIFFERENTIAL knobs at desired settings whichever applies 22 Increase the voltage with the Multi Tester or 6 Close the cabinet door variac until you hear relay K6 pick up 23 Decrease the voltage with the Multi Tester or variac until you hear relay K6 drop out 24 Readjust the PICK UP VOLTAGE and DROP i OUT DIFFERENTIAL knobs to give the des
115. ntenance or ad justments unless specified otherwise in the instructions then only using extreme caution due to danger of shock hazard Before using the disconnect plug if equipped for deenergizing the control panel be sure to place the operation selector switch on the generator set or automatic transfer to the STOP position Neglect of this procedure results in set starting and energization of the transfer switch generator side Use rubber insulative mats placed on dry wood platforms over floors which are metal or concrete when working on any electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling any elec trical equipment Jewelry is a good conductor of electricity and should be removed when working on the electrical equip ment Do not work on this equipment when mentally or physically fatigued WARNING TO AVOID POSSIBLE PERSONAL INJURY OR EQUIPMENT DAMAGE A QUALIFIED ELECTRI CIAN OR AN AUTHORIZED SERVICE REPRESENTATIVE MUST PERFORM IN STALLATION AND ALL SERVICE Power Generation Redistribution or publication of this document by any means is strictly prohibited TABLE OF CONTENTS GENERAL 2 Onan Semice Manual uu e xxu kr RS 3 ERES ALIE RERO 2 Model Number
116. ntrol fortwo wire starting in AT cabinet for three wire starting 3 Disconnect the starting batteries 4 Remove AC line voltage from the automatic transfer switch WARNING Failure to remove AC power from the automatic transfer switch and to disable the generator set presents a serious shock hazard during this modification d gt Remove the twist lock disconnect plug and open the control accessory panel REAR OF CONTROL ACCESSORY PANEL 8145 Remove the wire lead from transformer T1 ter minal T1 X3 and connect to terminal T1 X2 Figure 7 Remove the wire lead from resistor R1 terminal R1 3 and connect to terminal R1 2 See Figure 8 Remove the 24 volt battery charger module 6 number 300 0794 and replace with the 12 volt module number 300 0793 Hemove the 24 to 12 voit converter module 5 number 300 0848 and repiace with the 12 volt module number 300 0847 Spec A and Bonly Remove the 24 volt start stop 18 14 15 time delay module 7 number 300 0922 and replace with the 12 volt time delay module 300 0921 If module 10 is a 24 volt battery voltage sensor number 300 0797 remove and replace it with a 12 volt number 300 0796 sensor module 400 ampere AT only Remove the one screw from inside center support for left cabinet door and open door Remove the one screw on top and one screw on bottom from inside meter lamp panel flange Swing the meter lamp pan
117. ons or open circuit 6C Does AT have a start time delay K7 7C Has time delay K7 completed its delay 8C Does generator set start if terminal K7 1 is jumpered to K7 5 9C Replace relay K7 _ Three Wire Start 1C Place automatic transfer switch selector switch S2 to TEST Does generator set start 2C Has an engine overcrank occurred Check overcrank button on AT control accessory panel See generator set manual 4C Jumper terminal K5 1 to K5 2 Does generator set start and run 5C Replace cranking limiter assembly 6C Does AT have a preheat time delay for a diesel generator set 7C Has preheat time delay completed its delay 8C Does generator set start and run if terminal TBI H i 15 jumpered to TB1 3 9 Check preheat time delay circuit for an open and replace time delay if necessary 10C Jumper contacts K4 1 2 Does engine crank 11C Replace relay K4 12C Move selector switch back to NORMAL Does AT have automatic exercise clock Power Generation 14 YES 6 3C 4C 5 7C 8c 9C 12C 3C 5C 8C 9C 11C 13C NO 2C 2C 4C 6 10C 15C Redistribution or publication of this document by any means is strictly prohibited Continued 0 13C Does generator start and run if exerciser contact M1 4 is jumpered to M1 5 14C TOU 14 Replace the microswitch the exerciser cloc
118. ontacts 2 21 close to energize start relay K7 Contacts K7 4 7 close to energize the remote RMT line and start the generator set When the generator set comes up to speed and voltage relay K4 closes contacts K4 4 7 to energize the transfer switch through contacts K3 2 8 TB6 8 drawing 626 0106 TB7 8 relay coil K2 contact K1 C to generator line B to transfer the load from line to the generator set See Power Outage When the commercial line voltage returns to normal the voltage sensor opens the circuit between ter minals 8 10 to drop relay K6 drawing 626 0445 Contacts K6 1 7 close again to allow relay K3to be energized through plug in module 8 and the under voltage sensors See Restoration of Normal Line BATTERY VOLTAGE SENSOR The battery voltage sensor available in 12 volt or 24 volt versions is a plug in module with two relays mounted on the printed circuit board The battery voltage sensor module 10 monitorsthe battery charg ing system If the battery charger is exceeding a safe float voltage it lights the high battery voltage lamp DS14 If the battery float charger fails to charge the sensor lights the battery low voltage lamp 0513 Drawing 626 0445 shows the ground lead connecting to module 10 terminal 12 The battery positive line connects to module 10 terminal 19 If the battery charger is exceeding the high battery voltage sensor setting the sensor lights the high battery voltage lamp DS14 thr
119. ontacts 3 4 TB6 6 TB7 6 drawing 626 0106 to generator line A The K1 trip coil operates to release the mechanically held mechanism and to close contacts K1 IC Contacts 1 complete the circuit to energize the K2 closing coil from generator side terminal B Coil K2 then closes the main K2 contacts connecting the load to the generator side When transfer time delay K13 contacts close they also complete a circuit from generator line B closed contacts K1 IC TB7 12 drawing 626 0164 through the transformer T12 primary windings through TB 7 8 drawing 626 0106 TB6 8 drawing 626 0075 con tacts 1 3 K13 1 5 3 4 TB6 6 6 drawing 626 0106 to generator line A This circuit through T12 primary windings drawing 626 0164 induces a voltage in the transformer secondary windings to light the EMERGENCY lamp 0512 AREA PROTECTION Onan automatic transfer switches have provisions for connecting area protection equipment The normally closed output terminal of the area protec tion equipment connects to terminals TB1 4 and 5 see drawing 626 0075 A jumper between these two terminals must be removed before the protection equipment wiil operate the circuit The area protection equipment opens the circuit between 1 4 and 5 which removes AC input voltage from retays K3 and K7 Relays K3 and K7 are de energized as described under Power Outage When area protection equipment closes the circuit b
120. ory panel 400 ampere AT only Remove the one screw from the inside center support for the left cabinet door and open Proceed to Step 8 Remove the one screw on top and one screw on bottom from inside meter panel flange Open meter panel Loosen the latch pin on the edge of the meter panel or cabinet center support whichever applies and move the latch pin up or down in the slot as necessary Figure 10 Then tighten 400 ampere AT only Close the left cabinet door and reinstall the one screw Proceed to Step 11 Close the meter panel and reinstal the two Screws removed in Step 7 Close the control accessory panel If more adjust ment is necessary repeat Steps 5 through 11 Reconnect the twist lock disconnect plug LOOSEN LATCH PIN MOVE UP OR DOWN AS NEEDED FIGURE 10 ADJUSTMENT OF LATCH PIN Power Generation 2 Redistribution or publication of this document by any means is strictly prohibited 13 Restore AC line voltage to the automatic transfer switch Move operation selector switch to NORMAL in cabinet for three wire starting or RMT on engine control for two wire starting whichever applies Reconnect starting battery Close cabinet door EXERCISER CLOCK 1 Open the cabinet door of the automatic transfer switch 2 Move the operation selector switch on engine control for two wire starting in AT cabinet for three wire starting to STOP 3 Install a trip p
121. osed contacts K2 IC K1 CS closing coil K1 CC to normal line A Transfer switch contacts K2 open to remove the generator from the load and K1 contacts close to connect the load to the commercial power line After the stop time delay period time delay motor K9 closes contacts K9 7 8 to complete the circuit to energize relay K7 drawing 626 0075 Contacts K7 1 5 open to stop a two wire start generator set by removing from the RMT terminal To stop a three wire start generator set contacts K7 1 5 open drawing 626 0175 to remove battery ground from TB1 H and 3 and contacts K7 3 5 close to place battery ground on TB1 2 Power 10 SIMULATION OF POWER OUTAGE To ensure the equipment is ready to assume load properly if an actual power outage occurs the operator should periodically simulate a power out age Opening test transfer switch S1 de energizes relays K3 and K7 as described under Power Outage To end the test move test transfer switch S1 back to NORMAL drawing 626 0075 This closes the circuit to energize relay K3 as described under Restoration of Normal Line AUXILIARY CONTACTS ON LINE SIDE AND GENERATOR SIDE Small switches mounted on the transfer switch actuated by the moving armature provide dry con tacts to indicate transfer switch position Diagram 626 0106 shows the K1 auxiliary contacts S5 connec ting to TB9 terminals 1 2 and 3 The normally open contact connects to terminals 1 and 2 and the
122. ough a circuit from module 10 contact 21 TB6 3 626 0106 TB7 3 626 0164 0514 TB7 5 drawing 626 0106 TB6 5 to ground Contacts con nected to TB2 terminals 1 and 2 close drawing 626 0445 Contacts connected to TB2 terminals 2 and 3 open the battery charger has failed to charge the battery voltage will drop below the battery voltage sensor setting and it lights the low battery voltage lamp 0513 through a circuit from module 10 contact 17 TB6 4 drawing 626 0106 TB7 4 drawing 626 0164 DS13 TB7 5 drawing 626 0106 and TB6 5to ground The battery voltage sensor closes the con tacts connected to TB2 terminals 4 and 5 drawing 626 0445 and opens the contacts connected to TB2 terminals 5 and 6 to indicate a low battery voltage condition Redistribution or publication of this document by any means is strictly prohibited p Power 4 Generation a gt en riu Er Pa AT S WITH CONTROL PANEL GROUPS 51 THROUGH 55 NORMAL OPERATION Under normal conditions the commercial line supplies power to the load through the closed K1 contacts lines A B and C shown in schematic 626 0106 The closing coil CC of transfer switch K1 is originally energized from terminal A on the line side ihrough the closing coil CC normally closed K1 contact CS normally closed K2 contacts IC terminal W of receptacle J1 Terminal J1 W connects to terminal W of disconnect plug P1 drawing 626 0075 which connects
123. r set continues to run 1D Is control panel disconnect plug properly inserted into receptacle 2D Does automatic transfer switch have an exerciser clock eL IS exerciser turned to an exerciser period 4D Does AT have battery charging feature Check battery charging fuse F1 15 fuse OK 6D Is motor disconnect switch S8 closed 7D Is rated AC voltage present at transfer switch line terminals 8D Does AT have area protection equipment or a remote test switch connected to terminals TB1 4 and TB1 5 9D Jumper terminals TB1 4 and TB1 5 Does AT retransfer load to normal line at end of retransfer time delay if any 10D Check area protection equipment or remote test switch for malfunction circuit must close for retransfer 11D Is module 8 a transfer retransfer time delay 12D Has module completed its retransfer time delay to connect about 12 volts DC to relay K3 If not sure measure voltage from TB1 GND to TB4 18 13D Does AT transfer load to normal line if module 8 is replaced by a bypass plug 14D Replace transfer retransfer time delay module 8 15D Is module 11 a retransfer time delay the retransfer time delay has been returned to zero time for tests etc make sure the timer does not go back beyond zero Otherwise the generator set will not retransfer the load 16D Is motor timer module 11 POWER ON lamp lit 17D Has motor timer completed its time delay period 18D Heplace motor timer if it has stalled or does not
124. r switch shouid light at on engine control for 2 starting end of crank period Measure the crank time with 2 applies 9 stop watch or watch with second hand 6 change the time insert small screwdriver ine Dae 13 Close the cabinet door through the CRANK TIME holeinthefront of the 2 to 3 wire converter module Turn clockwise to increase the cranking time or counterclockwise to decrease the cranking time Make adjustments in small increments 7 Move test transfer switch to NORMAL 8 Push the PUSH TO RESET button on the 2 to 3 wire converter module 9 Repeat Steps 5 through 8 until the desired cranking time is obtained Move selector switch to desired position WITHOUT LOAD or WITH LOAD Close cabinet door Reconnect positive lead to generator set s starter or start solenoid 10 11 Tes Power TIME DELAYS CONTROL GROUPS 10 15 AND 20 25 Start Stop Time Delay Onan has set the time delay on start at 2 5 seconds time delay on stop at 5 minutes For other times use the following procedure You can set thedelay forthe start function from 0 1 to 15 seconds the stop function from 0 1 to 10 minutes 1 Open the right cabinet door of automatic transfer switch 2 Move selector switch to WITH LOAD 3 Move test transfer switch to TEST 34 Redistribution or publication of this document by any means is strictly prohibited Generation A Pa co oo 274 Anon
125. ransfer switches Do not use this bypass module for start stop time delay module 7 but rather use a start stop bypass plug module 1 Open cabinet door of automatic transfer switch 2 Position the operation selector switch at STOP on engine control for two wire starting or on automatic transfer switch for three wire starting 3 Remove the twist lock disconnect plug 4 Open the control accessory panel 5 Remove the module to be bypassed 6 Slide the keying plug s to the right and pull out from the printed circuit board receptacle Note position of the keying plug s when removing 7 Close the control accessory panel 8 Spec A and B Set switches S1 and S2 on the bypass module 300 0927 to the correct position instructions on bypass module printed circuit board for the particular bypass and insert the module See Figure 24 SWITCH S SWITCH 52 174 FUSE B152 FIGURE 24 BYPASS PLUG MODULE 9 Connect the disconnect plug reposition the the automatic transfer switch If the 1 4 ampere fuse on the bypass plug burns out check and correct switch positions then replace the fuse before inserting the bypass module again 10 Move the operation selector switch to STOP after test is finished 11 Remove disconnect plug and open control accessory panel 12 Take out bypass plug module and reinstall keying plug s removed in Step 6 13 Reinstall module from Step 5 or install new modu
126. red with selector switch in STOP or HAND CRANK positions For generator set operation move the selector switch on 2 to 3 wire converter module to NORMAL Lamp lights if power outage occurred with selector switch in STOP or HAND CRANK positions Power 52 Redistribution or publication of this document Generation by any means is strictly prohibited d USE OF BYPASS PLUG OR EXTENSION BOARD MODULE A bypass module plug can bypass the operation ofthe voltage sensors start stop time delay transfer time delay or retransfer time delay The extension board module extends the voliage sensor or time delay out from the control accessory panel to expose printed circuit components for troubleshooting testing etc Follow these instructions for the particular module Extension Board Module 1 2 Om Open cabinet door of automatic transfer switch Position the operation selector switch at STOP on engine control for two wire starting or on automatic transfer switch for three wire starting Remove the twist lock disconnect plug Open the control accessory panel Remove the plug in module Note position and remove keying plug s from the printed circuit board receptacle by sliding the plug s to the Insert extension board module into receptacle Insert module removed in Step 5 into the back of the extension module Figure 23 EXTENSION BOARD MODULE L wy 1
127. riac to these leads etc See Figure 14 Use instructions with Onan Multi Tester if used Note right side of terminal strip to see which terminal of T2 2 through T2 6 has an AC input lead for example a wire connected to T2 3 indicates 208 volts AC input On the left side of the terminal strip remove the corresponding transformer lead and tape it Figure 14 shows an example of this If this transformer lead is already removed and connected to variac or Onan Multi Tester because its nominal voltage matches transformer input voltage ignore this step Connect a voltmeter to the output leads of the variac Connect the variac to a 120 volt AC source Heconnect the disconnect plug Rear of control accessory panel and transfer switch energized Do not touch due to serious shock hazard Turn the DROP OUT DIFFERENTIAL knob s to minimum and the PICK UP VOLTAGE knob s to the clockwise limit maximum Adjust the Multi Tester or variacto give 120 volt output for the overvoltage sensor module Turn the PICK UP VOLTAGE knob on the sensor to be calibrated counterclockwise very slowly until you hear relay K6 close The knob should indicate 120 volts If not proceed to Step 18 li it does proceed to Step 19 Setting Too Low a Turn the DROP OUT DIFFERENTIAL knob counterclockwise to minimum b Turn the PICK UP VOLTAGE knob to the desired setting C Insert a small screw driver through the CALIBRATE hole a
128. rol for two wire starting and disconnect starting battery 3 Remove AC line power to the automatic transfer switch Be sure to remove AC line voltage from the automatic transfer switch and dis able ihe generator set Otherwise the automatic transfer switch presents a serious shock hazard 4 400 ampere AT only Remove the one screw from the inside center support for the left cabinet door and open 5 Hemove the two screws from the meter lamp panel s inside flange and open meter lamp panel 6 Locate the time delay assembly below the transfer switch on rear panel of cabinet Transfer time delay K11 for line side is located on the left time delay K12 for generator side is on the right 7 turn the knob on the time delay to be adjusted clockwise to increase delay increments marked on knob counterclockwise to decrease time perform the following 1 Remove the positive lead from the generator 8 Glose the meter lamp panel and secure with two start solenoid or starter 5 5 2 Open cabinet door of automatic transfer switch 3 Move selector switch to WITHOUT LOAD 4 Move 2 to 3 wire converter module 9 selector switch to NORMAL 9 400 ampere AT only Close the left cabinet door and secure with screw to cabinet center support Restore AC line voltage to automatic transfer swiich 5 Move test transfer switch to TEST Overcrank ns P 14 2 lamp on automatic transfe
129. ry paper to clean rusted sealing faces Remove ail traces of emery dust CONTACT CONTROL ROD 1716 IN 1 6 mm LATCHING LEVER CUTOUT SWITCH LATCHING LEVER 8146 FIGURE 22 LATCH MECHANISM MECHANICALLY HELD TRANSFER SWITCH Power 2 40 Redistribution or publication of this document Generation by any means is strictly prohibited TROUBLESHOOTING This troubleshooting section is divided into two main parts one for the automatic transfer switches with control accessory panels in groups 10 through 15 or 20 through 25 modular type panels and ono ior automatic transfer switches with control accessory panels in groups 51 through 55 relay type panels Those with control accessory panel groups 10 through 15 or groups 20 through 25 are covered first see below while those with groups 51 through 55 are started on page 69 AT S WITH CONTROL PANEL GROUPS 10 15 OR 20 25 Find the problem below and proceed to the page indicated Then answer the questions in the chart on that page either YES or NO Refer to the number in the column and proceed to that step etc INDEX See Page A Automatic transfer switch fails to immediately connect load to normal line when generator set is not operating 42 Automatic transfer switch fails to connect load to generator set when set runs during test with load or during a normal power outage 43 __ Automatic transfer switch fails to start generator set during a power o
130. s complete If the time delay is correct or time you desire proceed to Step 6 If not proceed to Step 5 Redistribution or publication of this document by any means is strictly prohibited exercise or tests 11 Close the cabinet door 5 Insert a small screwdriver through the TRANSFER opening upper opening in the front panel of the transfer retransfer time delay module Turn clockwise in small increments to increase the time delay counterclockwise to decrease time delay Transfer Time Delay Spec A and B TIME For adjustment or change of the transfer time delay transfer of the load to the generator set from the Standard setting two to three seconds use the TRANSFER following procedure LAMP 1 Open cabinet door of automatic transfer switch ANETE paui 2 Move operation selector switch to STOP on ADJUSTMENT engine control fortwo wire starting in AT cabinet for three wire starting 3 Move selector switch to WITH LOAD nethANEFEA 4 Remove the twist lock disconnect plug E 5 Open the control accessory panel ADJUSTMENT MN 6 Locate generator interposing relay K4 Figure TIMING COMPLETE 17 TIMING 7 Reconnect the twist lock disconnect plug with 2 T the control accessory panel open Rear of the control accessory panel and transfer switch are energized Do not touch due to serious shock hazard FIGURE 16 TRANSFER RETRANSFER TIM
131. stem Does this correct problem 22A Replace relay K3 Does AT have a programmed transition time delay assembly located in rear of standard cabinet below transfer switch 26A Does transfer switch operate if terminal 11 1 is jumpered to TB11 2 26A Repair or replace time delay K11 ET 10 Gra Power Redistribution or publication of this document 2 Generation by any means is strictly prohibited ta Continued NO 26A Is transfer switch mechanically held on generator side 27A 31A 27 Are generator side main contacts of transfer switch open 31A 28 2 Jumper normally open K2 interlock contacts series with 2 tripcoil Does transfer switch operate 29A 30A 20A Repair or replace normally open K2 interlock contacts 30A Is K2 trip coil open circuited or is trip coil mechanism obstructed 31A Is rated voltage across closing coil K1 CC 35A 32A 32A Does transfer switch operate if normally closed K2 IC contacts are jumpered 33A 34A 33A Repair or replace normally closed K2 IC contacts Repair or replace cutout switch K1 CS 35A Closing coil K1 CC is open circuited or switch mechanism is obstructed preventing transfer switch closure pi Power Redistribution or publication of this document Generation by any means is strictly prohibited B Automatic transfer switch fails to connect load to genera
132. tage sensors only one in position 13 for single phase AT Record pick up voltage dial settings with small pencil mark voltage sensor modules Turn pick up voltage knobs to 140 volts Does generator set stop after time delay After test return knobs to original settings Recheck the normal line voitage and output voltage of transformers T2 T4 and T5 for higher than norma readings Make sure voltage Sensors are set for correct pick up voltage 9F Are relay contacts K6 1 7 closed and making good contact 10F Measure K3 A B voltage for control groups 10 15 measure K3 1 2 voltage for control groups 20 25 If 9 volts or more the relay probably has an open coil Replace relay 11F Is relay K3 energized contacts K3 1 7 open and contacts K3 6 9 closed properly for control groups 10 15 or contacts K3 C NC open and contacts K3 3 5 closed properly for control groups 20 25 12 Remove start stop time delay module 7 and replace with the bypass plug module Does generator set stop 13F Replace start stop time delay module Power 49 Redistribution or publication of this document Generation by any means is strictly prohibited G Exerciser clock fails to start generator set YES NO 1G Does exerciser motor timer M1 operate Voltage on M1 1 2 should be approximately 120 VAC 5G 2G Has overcrank condition occurred note overcrank lamp on models 3G 3G Do conta
133. the hydrometer 2 Connect the voltmeter directly to the battery terminals 3 Measure the battery voltage If voltage is above the recommended float voltage proceed to Step 4 if the voltage is below the recommended float voltage proceed to Step 7 4 Open right cabinet door of automatic transfer switch 9 Insert a small screwdriver through the hole in the front panel of battery charger module 6 Turn counterclockwise in small increments to decrease the float voltage 6 After five minutes measure the battery terminal voltage again If voltage is still high repeat Steps 5 and 6 until voltage stabilizes atthe recommend ed float voltage Proceed to Step 11 7 Open right cabinet door of automatic transfer switch 8 Note charge current rate on charge ammeter on meter lamp panel 9 Insert a small screwdriver through hole in front panel of battery charger module 6 Turn clockwise in small increments to increase float voltage Note increase in the charging current on the charge ammeter on the meter lamp panel in approximately one hour or when charge current has decreased to initial value noted in otep 8 recheck battery terminal voltage Repeat Steps 8 through 10 until the battery terminal voltage stabilizes at the recommended float voltage Check the battery terminal voltage periodically during the first few weeks of operation Readjust the float charge rate if necessary Close the cabinet door 10 11 1
134. the line contacts the trip coil must be energized by generator output to disconnect the latch mechanism allowing the line contacts to open and generator contacts to close A mechanical interlock in the transfer switch prevents generator and line contacts from closing at the same time CONTACTS Contacts should never require cleaning or refacing for the life of the equipment except unusually dusty or dirty environments Discoloration of the silver does CONTACTS COVER REMOVED LOCKING SCREWS 2 MECHANICAL LATCHING LEVER 8146 ELECTRICAL INTERLOCK SWITCH not aifect their efficiency CAUTION Filing the contact face destroys the mating surfaces If the contacts ever do become burned or pitted replace them in the following manner Remove the plastic hood from the transfer switch Remove the washers and springs Lift the contacts from the slide posts Remove attaching screws from the stationary contacts 5 Install new contacts curved silver contact sur faces facing inward 6 Reassemble the springs and washers 7 Reinstall the plastic hood TRANSFER SWITCH COILS a transfer switch coil is grounded or has an open circuit replace by following appropriateinstructions for 30 ampere 60 through 100 ampere or 200 225 and 400 ampere transfer switch hon 30 Ampere Transfer Switch 1 Disconnect the coil lead wires an CONTACT FIGURE 21 MECHANICALLY
135. time out 19D Does control accessory panel have a manual automatic selector switch S3 and push to retransfer switch S4 20D Place manual automatic selector switch S3 in AUTO position Does automatic transfer switch retransfer load to line at end of retransfer time delay if used 21D Is voltage from TB1 GND to TB3 11 about 12 volts DC 22D Heplace voltage module 5 Power 4 Generation 40 11D 11D 15D 13D 19D 19D 19D 18D 21D 21D 22D Redistribution or publication of this document by any means is strictly prohibited omo D _ Continued YES NO SS 23D Does AT have overvoltage sensor modules 13 14 and 15 only one in position 13 on single phase AT 24D 31D 24D Has overvoltage sensor relay K6 energized to open contacts K6 1 7 25D 29D 25D Record pick up voltage dial settings with small pencil marks on voltage sensor modules 13 14 and 15 only one in position 13 for single phase Turn pick up voltage knobs to 140 volts or higher Does the AT retransfer the load to the normal line after retransfer time delay if any 260 27D 26D Recheck the normal line voltage and output voltage of transformers T2 T4 and T5 for higher than normal readings Make sure voltage sensors are set for correct pick up voltages ves 27D Remove one overvoltage sensor module from the control accessory panel Does AT transfer load to normal line after retransfer time delay if
136. to seal in relay K5 and contacts K5 4 and 7 close to energize relay K3 through automatic manual switch contacts 53 2 3 and voltage sensor modules 1 2 and 3 Relay contacts K3 2 8 open and contacts K3 6 9 closeto transfer the load from the generator to the normal line See Restoration of Normal Line Contacts K3 1 7 open to initiate the time delay in stop Automatic Position With automatic manual transfer selector switch S3 in the AUTOMATIC position relay K3 will pick up on normal power restoration through switch contacts S3 1 2 module 8 terminals 2 and 6 and voltage sensor modules 1 2 and 3 Relay K3 picks up to open K3 2 8 and close K3 6 9 to transfer the load from the generator set to the normal line See Restoration of Normal Line Contacts K3 1 7 open to initiate stopping of the generator set AC OVERVOLTAGE SENSOR Overvoltage sensors monitor the commercial line and start the generator set in case the commercial line exceeds the set voltage Drawing 626 0445 shows three voltage sensor modules 13 14 and 15 monitor ing a three phase system The solid state switches of all three voltage sensors connect in parallel so that if any one line voltage exceeds the voltage setting the voltage sensor will close its circuit between terminals 8 10 to energize overvoltage relay K6 Contacts K6 1 7 open to drop relay K3 Contacts K3 1 7 close to energize start stop time delay module 7 Time delay module 7 c
137. to normally open K3 contacts 6 5 and back to Y terminal of disconnect plug P1 P1 Y connects to terminal Y of receptacle J1 drawing 626 0106 which connects to line B on the line side of transfer switch mechanically held transfer switch on line side is picked up by the commercial line it is mechanically held in that position until the trip coil is energized The normal lamp 0511 on the meter lamp panel lights to indicate the presence of normal line power A circuit is completed from normal line A through TB7 11 drawing 626 0164 through transformer T11 primary windings TB7 10 drawing 626 0106 con tacts K2 IC receptacle J1 terminal W disconnect plug P1 terminal W drawing 626 0075 contacts K3 5 6 disconnect plug P1 terminal Y receptacle J1 terminal Y drawing 626 0106 to normal line B The primary of transformer T11 drawing 626 0164 in duces a voltage in the secondary windingstolightthe NORMAL lamp DS11 POWER OUTAGE When a power outage occurs normal line voltage from lines B and C drawing 626 0106 through disconnect plug terminals Y and Z disappears draw ing 626 0075 Relay K6 is de energized and contacts K6 3 5 open Relay K3 is de energized contacts K3 5 6 open and contacts K3 1 3 close Start time delay K7 is also de energized Two Wire Starting Start time delay relay K7 begins its time delay When the time delay ends contacts K7 1 5 close to connect battery positive
138. tor set when set runs during test with load or a normal power outage YES 2B 18 ls generator output near rated voltage 2B Does have NORMAL and EMERGENCY indicating lamps 3B 4B 3B Is EMERGENCY lamp lit 23B 4B 4B Does AT have a transfer time delay K13 5B 8B 5B Is time delay completed 6B 6B Does transfer switch operate if terminal K13 1 is jumpered to K13 5 jumper K13 1 to K13 2 for 480 or 600 volt system 7B BB 7B Repair or replace transfer time delay K13 8B Is transfer inhibit circuit connected to terminals 11 and 12 9B 11B 9B Does AT transfer load if terminal TB6 11 is jumpered to TB6 12 10B 11B 10B Check for malfunction in inhibit circuit 11B Does AT have a programmed transition time delay assembly located in rear of standard cabinet below transfer switch 12B 14B 12B Does transfer switch operate if terminal TB11 5 is jumpered to TB11 6 13B 14B 13B Repair or replace time delay K12 14B Are contacts K3 1 3 5 6 for 480 or 600 volt systems closed and making good contact 16B 15B 15B Replace relay K3 16B Are line side main contacts of transfer switch open 20B 17B 17B Jumper normally open K1 interlock contacts in series with K1 trip coil Does transfer switch operate 19B 18B Repair or replace normally open K1 interlock contacts as needed 19B Is K1 trip coil open circuited or is trip mech
139. ups 10 15 and 20 25 To convert a two wire start control automatic transfer switch to three wire start use the following procedure 1 Move the operation selector switch on the engine control to STOP 2 Disconnect the starting batteries 3 Remove AC line voltage from the automatic transfer switch WARNING Failure to remove AC power from the automatic transfer switch and to disable the generator set presents a serious shock hazard during this modification 4 Open the automatic transfer switch cabinet door 5 Remove the remote start wire leads between ihe engine control remote terminal block and the Power Generation 25 automatic transfer switch terminal block 1B1 6 Remove the 300 0937 blank spare module 9 and replace with a 300 0926 2 to 3 wire converter module 7 Check battery voltage battery must be a 12 voit unit If DC system was 24 volts make the conversion Changing Control Accessory Panel DC System Voltage described in this section 8 Connect automatic transfer switch to terminals TB1 B 1 and 3 to the three wire start engine control 9 Restore AC line voltage to the automatic transfer switch Connect the starting batteries Move the operation selector switch on the 2 to 3 wire converter module 9 to NORMAL Close the cabinet door 10 11 12 THREE TO TWO WIRE START CONVERSION 12 VOLTS This procedure applies only to control accessory panels in groups 10
140. utage 45 Automatic transfer switch fails to automatically retransfer load from generator set to line after normal power returns Generator set continues to run 47 Automatic transfer switch delays transferring load to line until generator set stops after normal power outage 49 Generator set starts during normal service _ gt 4 G Exerciser clock fails to start generator set H Battery charger malfunctions Overcrank lamp lights while generator set is running AT E only 51 J Overcrank lamp lights without any engine cranking only 52 Use of Bypass Plug or Extension Board Module see page 53 Module Test Procedures see page 54 HEN For modular solid state control accessory panels use any tin edge contact boards still in your stock for replacement only in Spec A and Spec B AT transfer switches After depleting the stock use only boards with gold edge contacts for all AT transfer switches any AT can use a board with a gold edge contact g Power 1 Redistribution or publication of this document d Generation by any means is strictly prohibited A Automatic transfer switch fails to immediately connect load to fine when generator set is not operating YES N Is normal line energized and delivering rated voltage to the line terminals of the transfer switch 2A Is control panel disconnect plug properly inserted into receptacle 3A Does automat
141. vide by the factor to see if the reading is correct If it is proceed to Step 7 If not proceed to Step 6 Turn the PICK UP VOLTAGE knob to its clockwise limit then counterclockwise to desired setting b Insert a small screwdriver through the CALIBRATE hole and turn counterclockwise very slowly until you hear relay K3 pick up Setting Too High a Turn the PICK UP VOLTAGE knob to its clockwise limit b Insert a small screwdriver through the CALIBRATE hole and turn to its clockwise limit c Turn the PICK UP VOLTAGE knob to desired setting d Turn the CALIBRATE adjustment counterclockwise very slowly until you hear relay K3 pick up Repeat Steps 3 through 6 for each undervoltage sensor If these calibrations are satisfactory for your application make the sensor seitings See Undervoltage Sensor Settings near end of sec tion Fora more accurate calibration and calibration of the DROP OUT DIFFERENTIAL knob use the Onan Multi Tester or a variac and use the follow ing procedure STEPDOWN TRANSFORMER T2 TERMINAL CONNECTIONS 0 1 NOTE CONNECTIONS SHOWN FOR UNDERVOLTAGE SENSOR AND OVERVOLTAGE SENSO 13 10 11 12 29 96 Jum SN Remove the twist lock disconnect plug and open the control accessory panel On the back side and top left of the control accessory panel remove the white plastic cover which covers the transformerterminals for T2 and T3 Figure 13
142. y of 2 4 seconds close switches 1 2 and 3 and open switch 4 For a 345 seconds delay on stopping generator set close switches 5 7 and 8 and open swiich Insert the time delay moduleback into the control accessory panel Close the cabinet door TABLE 1 PROGRAMMABLE TIME DELAY Pi ee er PROGRAMMABLE START STOP TIMER SWITCH CLOSED SWITCH OPEN SWITCH POSITIONS __ 2 24 To staat 5 6 7 8 TOSTOP TIME C Q 0 5 sec 1 0 sec C 1 4 C C 2 4 C O 5 5 sec 7 9 C C 9 6 sec 43 62 sec C C 76 sec C C c 345 sec C 615 sec TIME TOL 20 Transfer Retransfer Time Delay Begin Spec C This module has factory settings of 2 5 seconds for delay on transfer and 10 minutes for delay on retransfer To change delay times use the following procedure and refer to Figure 16 The transfer time delay function has a time range of 0 1 to 15 seconds the retransfer delay function has atime range of 0 540 30 minutes 1 2 Move the test transfer switch to TEST Open the cabinet door of the automatic transfer switch Move the selector switch to WITH LOAD The generator set will start and run With a stopwatch or watch with a second hand measure the time the red transfer LED onthetime delay module 8 remains lit The red LED will turn off after the time delay i
143. ystem For higher voltage systems the PICK UP VOLTAGE knob readings are multiplied by the following multiplying factors VOLTAGE MULTIPLYING FACTOR 120 1 0 208 1 73 240 2 0 480 4 0 600 5 0 If you wish to check the calibration of the sensors before making the settings see Undervoltage Sensor Calibration or Sensor Calibration whichever applies Otherwise see Undervoltage Sen sor Settings or Overvoltage Sensor Settings Refer to Figure 12 VOLTAGE SENSOR VOLTAGE SENSOR VOLTAGE SENSOR DIFFERENTIAL DIFFERENTIAL 15 15 5 OW PIRENTIAL PICK UP VOLTAGE KNOB FOR PICK UP VOLTAGE 90 TO 40 VOLT READINGS FIGURE 12 VOLTAGE SENSORS Undervoltage Sensor Calibration 1 Open the cabinet door of the automatic transfer switch 2 Move the operation selector switch to STOP on engine control for two wire starting in cabinet for three wire starting Turn all the undervoltage sensor knobs to minimum voltage setting 4 Turn the PICK UP VOLTAGE knob the sensor io be calibrated to its clockwise limit 5 Turn the PICK UP VOLTAGE knob very slowly counterclockwise until you hear relay K3 pick up This reading timesthe multiplying factor for your system voltage should equal the line voltage 28 Redistribution or publication of this document by any means is strictly prohibited Generation il Setting Too Low Check line voltage with a voltmeter di

(spec A-C) Transfer Switch Service Manual (08

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