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(spec E-F) Transfer Switch Service manual (12

1. JO 38 er zd HANDLE p ASSEMBLY BEST 0577 0 A Je Hc mm JUMPER BUS BAR 1 PLACE THIN COAT OF ELECTRIC JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES 2 TORQUE SHALL BE 25 30 iN LBS FOR 10 32 SCREWS 3 TORQUE SHALL BE 70 75 IN LBS FOR 1 4 20 SCREWS 4 TORQUE SHALL BE 10 12 FT LBS FOR 5 16 18 SCREWS 5 TORQUE SHALL 18 20 FT LBS FOR 3 8 16 SCREWS 6 PLACE A THIN COAT OF THREAD SEALANT TO THREADS OF SCREW THEN TORQUE AS NOTED INSULATOR FIGURE 27 FRONT CONNECT TRANSFER SWITCH ASSEMBLY lt Power Redistribution or publication of this document Generation by any means is strictly prohibited 400 MODEL SPEC E INTERLOCK INTERLOCK 3 3 5 ARM BAR 4 HANDLE JUMPER BUS ASSEMBLY BAR 1 PLACE THIN COAT OF ELECTRIC JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES 2 TORQUE SHALL 25 30 IN LBS FOR 10 32 SCREWS 3 TORQUE SHALL BE 70 75 IN LBS FOR 1 4 20 SCREWS 4 TORQUE SHALL BE 10 12 FT LBS FOR 5 16 18 5 5 5 PLACE A THIN COAT OF THREAD SEALANT TO THREADS OF SCREW THEN TORQUE AS NOTED 1 2 LOAD BUS BAR REAR CONNECT STRAP FIGURE 28 REAR CONNECT TRANSFEH SWITCH ASSEMBLY Power 50 Redistribution or publication of this document Generation by any means is strictly prohibited 400 MODEL SPEC E REAR CONNECT FRONT CONNECT CHUTE BARRIER CONTACT ARC CH
2. ew cee 3 0 3 pens aS 3 Eu M 10 AGIUSBIGHIS uu oct Rr Ronan d Ree serra UR V RODEO RE NON RUE 11 Relay Control 14 ol TP 14 2 sassa 14 Sri e 16 Options and Accessories aes 20 INMOGUCHON 20 ClOCK rr PT 20 Electronic Exerciser Clock 0 ccc ce cen ence ccc ence 21 Programmed Transition 5 22 Battery Float Charger 0 2 ce ccc cen cee en reece asset eire 23 Battery Trickle Charger iss esee pare eine ses UE doc OR Ead 24 Two to Three Wire Converter 24 Transfer Switch ehh ham enn 26 tc nrc M EE 26 Linear Actuator Removal and Replacement 40 70 100 26 Switch Assembly Removal and Replacement 40 70 100 Amp 28 Auxiliary Switch Removal and Replacement 40 70 100
3. JA LE E Del HO eem EMER pes E T O S8 L O v AUXILIARY SWITCH LEVER POSITION WHEN TRANSFER SWITCH 15 CLOSED 1 2 _ 7 JUMPER BUS BAR LOAD BUS BAR 1 2 55559553555 1 222 VIEW D D MAIN CONTACTS CLOSED SECTION A A 1 PLACE THIN COAT OF ELECTRICAL JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES 2 TORQUE 25 30 IN LBS SECTION B B 3 TORQUE TO 15 20 IN LBS 4 TORQUE TO 70 75 IN LBS 5 AUXILIARY SWITCH LEVER MUST TURN FREELY WITH OPERATION OF TRANSFER SWITCH FIGURE 15 REAR CONNECT TRANSFER SWITCH ASSEMBLY Power 31 Redistribution or publication of this document Generation by any means is strictly prohibited d lt 40 70 100 AMP MODEL 1 APPLY THIN COAT OF ELECTRIC JOINT COMPOUND BETWEEN CURRENT CARRYING PARTS 2 TORQUE TO 28 32 IN LBS 3 TORQUE TO 16 20 IN LBS FRONT CONNECT 4 TORQUE TO 70 75 IN LBS REAR CONNECT CONTROL WIRING RING TERMINAL CONTACT POWER SOURCE LEAD TERMINAL SQUARE HOLE THIS SIDE pan J 1 211 E SEE Tk CONTROL WIRING x i REAR TERMINAL 2 U STRAP CONNECT 3 STRAP FIGURE 16 FRONT AND REAR CONNECT SWITCH ASSEMBLY On front connect switches install the power source supply wires and secur
4. 33 Linear Actuator Removal and Replacement 150 260 35 Switch Assembly Removal and Replacement 150 260 Amp 38 Auxiliary Switch Removal and Replacement 150 260 42 Linear Actuator Removal and Replacement 400 Amp Spec E 44 Switch Assembly Removal and Replacement 400 Amp Spec E 47 Auxiliary Switch Removal and Replacement 400 Amp Spec E 53 Linear Actuator Removal and Replacement 600 800 1000 Amp 55 Switch Assembly Removal and Replacement 600 800 1000 57 Auxiliary Switch Removal and Replacement 600 800 1000 Amp 62 Linear Actuator Removal and Replacement 400 600 Amp Spec 65 Switch Assembly Removal and Replacement 400 600 Amp Spec F TELLS 67 Auxiliary Switch Removal and Replacement 400 600 Amp Spec 71 Trou bleshooting hh hat hate snnt 73 Power Redistribution or publication of this document e Generation 1 by any means is strictly prohibited Introduction ABOUT THIS MANUAL This manual contains service procedures for the OT Il utility to genset automatic transfer switch Thisincludes models with either the Power Sentry or relay control and with two or three
5. 71 PLA AAI E AC ET a SOURCE SESE SESS mal Sse TRANSFORMER s ENCLOSURE ald PSO Si AP Ad Ad dk 4 old LIGHT ARRAY K4 AND K5 M RELAYS CARD EDGE CONNECTORS MOTHER BOARD ndi zu T ASSEMBLY Hr J2 K3 RELAY J1 _ i u C1 STORAGE TM CAPACITOR 1 RIA ALPE Pg SOURCE 1 TRANSFORMER ASSEMBLY C12 FILTER CAPACITOR REVERSING CONTACTOR FIGURE 1 POWER SENTRY CONTROL Power 4 Generation bysso LE 111 n r jy Ill J T T il I qip n I m fen ender by 96 eee P hi i of pod p I i il li yo l L 41 F 1 II 1771 Z a sasa se 2 aer I T M j tA o d 5 il r1 li E 228 re II i T II bes Lou Ny gt 4 I S Md 5 rn iir 1 c l I 1 ty roy zh tri d i EE RE z i _ Fg t il 49 EN l l f y 3l ee i ET b rr TT Sel il rae tt t t rl H l B n 5 1 I h pcm I S N
6. MN Sg I i UJA SUE o K 7 C r JUMPER BUS BAR HANDLE ASSEMBLY 1 PLACE THIN COAT OF ELECTRIC JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES 2 TORQUE SHALL BE 15 20 IN LBS FOR 18 32 SCREWS 3 TORQUE SHALL BE 25 30 IN LBS FOR 10 32 SCREWS 4 TORQUE SHALL BE 70 75 IN LBS FOR 1 4 20 SCREWS 5 TORQUE SHALL BE 10 12 FT LBS FOR 5 16 18 SCREWS OR NUTS THREADED HEX SPACER SECTION B B 23 Ls NE iden la er JUMPER BUS BAR m 5 INSULATOR BUS BAR FIGURE 21 FRONT CONNECT TRANSFER SWITCH ASSEMBLY p Power 39 Redistribution or publication of this document Generation by any means is strictly prohibited E Rn 150 260 MODEL REAR CONNECT STRAP INTERLOCK BAR 9 INTERLOCK ARM 2 4 Jan 2 op Ds us E 198007 g E PE jt HANDLE ASSEMBLY 1 PLACE THIN COAT OF ELECTRIC JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES THREADED HEX SPACER 2 TORQUE SHALL 15 20 IN LBS FOR 8 32 SCREWS 3 TORQUE SHALL 25 30 IN LBS FOR 10 32 SCREWS 4 TORQUE SHALL 70 75 IN LBS FOR 1 4 20 SCREWS SECTION B B 5 TORQUE SHALL 10 12 F
7. S7 C etc for identification Refer to Figure 24 for identification of auxiliary switch terminals Place red plastic switch cover in position and secure with machine screws 4 and flat washers 4 Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque Plug in the three control wiring harness plugs J1 J2 J3 and reconnect the normal power source and emergency power source If a generator set is the emergency power source connect the nega tive battery cableto the starting battery and place operation selector switch in automatic or remote position Redistribution or publication of this document by any means is strictly prohibited 150 260 AMP MODEL FLAT WASHERS MACHINE SCREW INSULATING BARRIER BRACKET SWITCH LEVER AUXILIARY SWITCH LEVER IN CLOSED POSITION 1 ORIENTATE TERMINALS ON 3 AND S6 AS SHOWN N O SECTION A A NORMAL EMERGENCY SIDE WITH TWO SWITCH TERMINALS LI FIGURE 24 AUXILIARY SWITCHES LINEAR ACTUATOR REMOVAL AND REPLACEMENT 400 Amperes Spec E Disconnect both the normal and the emergency power source from the transfer switch before servic ing If a generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the set starting battery The selector switch is located on the generator set control panel for tw
8. Service Manual Transfer Switches 962 0504 SPEC E F 12 88 Printed in U S A Power M RM Redistribution or publication of this document Generation by any means is strictly prohibited Safety Precautions This manual includes the following symbols to indicate 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 personnel and the equipment DANGER This symbol warns of immediate hazards that will result in severe per sonal injury or death This symbol refers to a hazard or A WARNING unsafe practice that can result in severe personal injury or death This symbol refers to a hazard amp CAUTION unsafe practice that can result personal injury or product or properly damage High voltage in OT transfer switch components pre sents serious shock hazards that can result in severe personal injury or death Read and follow suggestions Keep the transfer switch cabinet closed and locked Make sure only authorized personnel have the cabinet and operational keys Due to the serious shock hazard from high voltages within the cabinet all service and adjustments to the transfer switch must be performed only by an electrician or authorized service representative If the cabinet must be opened for any reason 1 Move the operation selector switch on the genera tor set or Stop
9. p o dq M G zb KaG d ry START TS al oy DISCONNECT mt RELAY Ric NU i OVERCRANK RELAY OPTIONAL PREHEAT TIME DELAY SC 1140 FIGURE 11 TWO TO THREE WIRE CONVERTER High voltages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from the transfer switch before servicing Overcrank Relay 1 Open the transfer switch cabinet door 2 Determine the overcrank time delay required The standard overcrank relay has a range of 0 6 to 60 seconds The optional relay with the Failed to Start contacts has a range of 6 to 60 seconds he relay adjustment settings are marked in increments that range from 0 to 100 percent 100 percent setting equals a 60 second delay a 50 percent setting equals a 30 second delay etc Turn the knob clockwise to increase the delay and counterclockwise to decrease the delay If the optional preheat time delay is included go on to the next section If the preheat time delay is not included close the cabinet door and recon nect the normal power source Connect the negative battery cable to the starting battery and place the set operation selector switch in the automatic position Power Generation 23 Preheat Time Delay Open the transfer switch cabinet door Determine preheat time delay required
10. All adjustments are made by inserting a screwdriver through the small openings in the module panel and turning a potentiometer Place the Motor Disconnect Switch on the transfer switch in the manual or down position before making any adjustments Return the switch to the up position after adjustments are complete High voltages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Use extreme caution when making adjustments to avoid touching high voltage components Voltage Sensor Modules A separate voltage sensor see Figure 3 is used for H each power source The voltage sensor above the time delay module is for the emergency power source source 2 and the sensor below the time delay module is for the norma power source source 1 Undervoltage Sensor The standard voltage sensor modules monitor the Normal and Emergency power source for an undervoltage condition The under voltage range of adjustment is shown below If other than factory setting is desired align the slot on the potentiometer to the desired markings on the module panel J ADJUSTMENT FACTORY FUNCTION RANGE SETTING Dropout 75 to 98 85 Pickup 85 to 100 95 If necessary the undervoltage sensor for either the Normal or Emergency sources may be calibrated as follows 1 Ensure that nominal voltage is present on alil phases of the source being calibrated Normal or Emergency On
11. Apply a thin coat of electric joint compound between the mating surfaces of the block assem bly and the lug terminal front connect or block assembly and rear connect strap rear connect On front connect switches install the lug termi nals onthe block assemblies and secure with hex head capscrew and spring washer Tighten to 28 to 33 ft Ibs 40 0 to 44 7 Nem torque On rear connect switches install the rear connect straps on the block assemblies and secure with hex head capcrew and spring washer Tighten to 28 to 33 ft lbs 40 0 to 44 7 Nem torque Place each block assembly in position on the base and secure with hex head capscrews 8 lock washers 8 and flat washers 8 Refer to Figures 33 and 34 to determine where the spac ers are required and where the short capscrews should beinstalled Tighten capscrews to 70to 75 in Ibs 7 9 to 8 5 Nem torque On front connect switches install the power source supply wires and securely tighten the lug terminals On rear connect switches apply a thin coat of electric joint compound between the mating surfaces of the contact strap and rear connect strap see Figure 34 Secure with hex head capscrew flat washers spring washers ring _ terminal and nut Tighten to 10 to 12 ft ibs 13 6 to 16 3 Nem torque Connect the control wiring leads to the corres ponding power source terminals Control wires are marked NORM A B C or EMER A B C for identification
12. Apply a thin coat of electric joint compound between the mating surfaces of the jumper bus bars the braided strap connectors and load bus bars Install the jumper bus bars and secure to the switch assemblies with hex head capscrews spring washers and bushings Tighten to 18to 20 ft lbs 24 4 to 27 1 Nem torque Secure the jumper bus bars to each load bus bar with a hex head capscrew ring terminal lower row only flat washer spring washer and nut Tighten to 10 to 12 ft Ibs 13 6 to 16 3 Nem torque Connect the control wiring leads to the corres ponding jumper bus bar terminal Control wires are marked LOAD A B C for identification Power Generation 62 13 Install the interlock bar and secure to each inter lock arm with a hex head capscrew locking washer and flat washer Tighten to 70 75 in Ibs 7 9 to 8 5 Nem torque 14 Place the arc chute covers in position over the arc chutes and replace the red plastic contact covers 15 Replace the linear actuator as described in Linear Actuator Removal and Replacement section for 600 Spec E 800 1000 Ampere switches Follow steps 1 through 10 in the Replacing Actuator section 16 Test switch for proper operation and close cabinet AUXILIARY SWITCH REMOVAL AND REPLACEMENT 600 Spec E 800 1000 Amperes Disconnect both the normal and the emergency power source from the transfer switch before servic ing generator set provides standby emergency p
13. The A10 Stop Time Delay holds the K3 relay circuit open unti the stop time delay has timed out At the end of the time delay the circuit closes and output voltage from the T1 transformer energizes the K3 relay The K3 contacts open the start circuit which sends a stop signal to the generator set 19 Redistribution or publication of this document by any means is strictly prohibited Options and Accessories INTRODUCTION This section covers the adjustment and service procedures for the options and accessories that are available with the transfer switch Separate installation instructions are furnished with each option Refer to the appropriate instruction sheet for wiring connections and installation procedures The location of each option is shown in Figure 7 L m x Ax Vag Nahe a S M w h b I 98 Sag e FIGURE 7 TYPICAL OPTIONS Power _ Generation a ma CY M 2S ENT gt a t n EXERCISER CLOCK The exerciser clock is set by the factory to provide one half hour of exercise each week Onan recom mends that the generator set be operated under load for 30 minutes each week to remove moisture and to keep a film of lubricating oil on the engine parts Exercising for one long period is better than several
14. 1 4 1 a K LI gt TURN SPOKED WHEEL COUNTERCLOCKWISE TURN LARGE DIAL J CLOCKWISE ONLY NOTE Trip pins are left hand thread SC 1138 FIGURE 8A EXERCISER CLOCK Power 21 Generation 3 To set the time of day you want the generator set to stop use the outside row of holes on the large dial Install a trip pin in the hole that corresponds to the desired set stop time 4 Install a trip pin in the small spoked wheel for each day that no exercise is desired 5 Rotate the large dial clockwise until the correct time of day aligns with the pointer 6 Rotate the small spoked wheel counterclockwise until the correct day aligns with the pointer Sixteen trip pins are supplied Store any unused pins on the time pointer bracket 7 Set the exerciser switch so that the generator set will exercise with or without load as desired 8 Glose the cabinet and reconnect the normal power source and emergency power source Connect the negative battery cable to the starting battery and place the set operation selector switch in automatic or remote position ELECTRONIC EXERCISER CLOCK Field Installed Option The electronic exerciser clock initiates generator set start run cycles at programmable intervals and for pro grammable durations It is a 7 day 24 hour clock that can store and execute up to ten start stop programs exercise cycles Programming the exerciser clock requires sett
15. I 12 appears in the upper left display window The I is a symbol for start time 3 Press the h button 3 to Set the start hour Press the m button 4 to set the start minute 5 Press the 1 7 button 5 to advance the indicator bar 13 from 1 to 7 and back to 1 For each day to be selected for exercise press the Q button 7 when the indicator is over the desired day number 1 represents Sunday D To set the exercise stop time 1 Press the 1 button 2 An O 15 appears in the lower left display window The O is a symbol for stop time 2 Press the h button 3 to set the stop hour Press the m button 4 to set the stop minute 4 Pressthe 1 7 button 5 to advance the indicator bar 14 from 1 to 7 and back to 1 For each start time selected in step 5 above there must be a corres ponding stop time program can start on day 2 passthrough midnight and stop on day 3 for exam ple but there must be a stop time for every start time Press the Q button 7 when the indicator is under the desired day number 5 To enter the complete start stop program press the Pr button 8 If all program requirements have been satisfied the display returns to the time of day If the program requirements are not met the display ofthe section that needs correction flashes on and off Q3 To enter more programs repeat the two 5 step proce dures maximum of ten programs can be entered The same
16. holds open the K6 contacts which opens the K1 and K3 relay circuit The output voltage from the T1 transformer energizes the K4 relay and causes it to begin timing out When the retransfer time delay has timed out the normally open K4 contacts close This connects the T1 output terminal to the K1 Reversing Contactor relay and to the A10 Stop Time delay which is wired in series with the K3 Start Time Delay relay The other side of the K1 and K3 relays is connected to the normal line side Power _ Generation Output voltage from the T1 transformer energizes the K1 relay This closes the normally open K1 contacts sets and opens the normally closed K1 contacts 1 set Opening the normally closed K1 contacts opens the K2 relay circuit Since the K2 relay is already de energized opening the K1 contacts provides an electrical interlock that prevents the K1 and K2 relays from energizing at the same time Closing the normally open K1 contacts connects line to line voltage from the norma side to the linear actuator motor This energizes the linear actuator and causes to open the transfer switch on the emer gency side and then close the transfer switch to the normal side When the transfer switch closes to the normal side the S2 auxiliary switch opens the linear actuator circuit which de energizes the linear actua tor The transfer switch remains closed to the normal side and the load is now powered by the normal power source
17. short periods The normal exercise period is from 12 00 to 12 30 pm on Saturdays If this schedule is not satisfactory the exerciser program may be changed using the following procedure PROGRAMMED TRANSITION THREE WIRE STARTING CONTROL OVERCRANK RELAY PREHEAT TIME DELAY BATTERY CHARGER 5 1093 Redistribution or publication of this document by any means is strictly prohibited Disconnect both the normal and the emergency power source from the transfer switch before servic ing Turn the operation selector switch for the gener atorsetto STOP and disconnectthe negative battery cable from the set starting battery The selector switch is located on the generator set control panel on two wire start systems and on the transfer switch control panel on three wire start systems High voltages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from the transfer switch before servicing 1 Open the transfer switch cabinet door 2 time of day you want the generator set to start use the inside row of holes on the large dial see Figure 8A Instali a trip pin left hand thread in the hole that corresponds to the desired set starting time 1 LI at PU V b M a t m r es p LI i Bog IN E LI L 1
18. y B Utility to utility C GenSet to utility D GenSet to genset 4 Enclosure NEMA 1 NEMA Open construction D Watertight NEMA 4 5 Continuous ampere rating 6 Voltage code n 60 Hz 50 Hz Voltage Phase 1 5 120 1 3 53 120 240 1 4 54 120 208 3 4X 54X 277 480 3 5D 55D 120 240 3 7 57 220 380 3 7X 57 240 416 3 8 58 127 220 3 9X 347 600 3 7 Agency Cer tification Underwriters Laboratories inc C Canadian Standards Association N None 8 Control Group 31 through 34 Power sentry 56 through 58 Relay control 91 through 94 Manual control 9 Meter Group None 2 through 10 Combination of AC voltmeter AC ammeter running time meter and frequency meter 40 Specification letter Advances with production modifications Redistribution or publication of this document by any means is strictly prohibited Power Sentry Control INTRODUCTION The Power Sentry control is a solid state electronic control designed for use with automatic transfer switches Power input is taken from either of the two connected sources Adjustable plug in type voltage sensor modules provide for several voltage sensing options The time delays are also contained on a plug in type module and are adjustable for applica tion requirements All components for the Power Sentry control are mounted within a separate enclosure A viewing win dow
19. 2 through J6 P6 3 to P S K3 socket positions 9 and 10 0 Is 12 VDC available at P S J2 13 to ground Replace mother board Is 12 VDC available at P S J2 5 to ground new time delay card ls 40 VAC available at P S TB1 3x1 to LS Check operation of 512 5 and 6 contacts using key switch Is 40 VDC single phase 50 VDC three phase available at P S J1 14 Try new line side voltage sensor Replace mother board Ox OM X xXx OK m gt x X X X OX h gt X x Xx gt x x 2 xx x Power 80 Redistribution or publication of this document Generation by any means is strictly prohibited A WARNING The following troubleshooting procedures present hazards that can result in severe personal injury or death Only qualified service personnel with knowledge of eleciricily fuels and machinery hazards should perform service procedures A WARNING Improper operation of the generator set presents a hazard that can cause severe personal injury death Observe all safety precautions in your generator set manuals A WARNING High voltages within the cabinet and ihe rear side of the cabinet door present a shock hazard that can cause severe personal injury or death Use exireme caution to avoid touching electrical contacts when the cabinet door is open Remove all power sources before removing and replacing components Sectio
20. CAPSCHEW WITH LOCK WASHER FIGURE 13 LINEAR ACTUATOR Secure actuator motor to switch assemblies using socket head capscrews 4 flat washers 8 lock washers 4 and nuts 4 Be sure to recon nect ground wire to lower left screw see Figure 12 Tighten capscrews to 25 to 30 in Ibs 2 8 to 3 4 Nem torque Do nol overtighten screws or the ACAUTION switch assembly can be damaged 4 Connectthe black actuator lead wire to the circuit breaker and the red and white actuator lead wires to the following capacitor terminals Red Lead Wire Connect to capacitor terminal with S3 lead wire White Lead Wire Connect to capacitor terminal with S7 lead wire Transfer switches for voltage ranges 347 380 416 440 480 and 480 use two capacitors C1 and C2 wired together in series single jumper wire is placed between one of the terminals on C1 and one of the terminals on C2 Connect red and white leads as described in previous section Use wire ties to hold actuator lead wires in place with rest of wiring harness Check operation of transfer switch and alignment of actuator rod by manually opening and closing both the normal and emergency switch assemblies m Power Generation 7 Place red plastic switch cover in position and secure with machine screws 4 and flat washers 4 Tighten to 25 to 30 in ibs 2 8 to 3 4 Nem torque 8 Pluginthethree control wiring harness plugs J1 2 and J3 and
21. Check pins 11 and 13 in J3 P3 B Check connection at TB2 9 C Check pins 11 and 13 in P S J4 P4 Check switch S6 40 70 100 amp S5 above 100 amp Is line to line voltage available at K12 2 to 8 Gheck K12 relay contacts Is line to line voltage available at linear motor black to red leads Check linear motor windings and capacitor assembly A Check pins 1 and 3 in P S J4 P4 B Check pins 1 and 3 in J3 P3 C Check motor disconnect switch 1 D Check CB1 E Check switch S3 Powe r 18 Redistribution or publication of this document Generation by any means is strictly prohibited A WARNING The following troubleshooting procedures present hazards that can resuit in severe personal injury or death Only qualified service personnel with knowledge of electricily fueis and machinery hazards should perform service procedures improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safely precautions in your generator set manuals A WARNING High voltages within the cabinet and the rear side of the cabinet door present a shock hazard that can cause severe personal injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove all power sources before removing and replacing components Section 2 Wire Starting Generator Set Doesn t Start During Power Failure Simulated Power
22. Failure or Exercise Will generator set start from its own control Is battery voltage available at TB1 3 Is battery voltage available at TB1 2 Check leads between generator set and transfer switch Check jumper between TB1 2 and 3 Will generator set run if TB1 3 is jumpered to TB1 4 Is the P S relay de energized A Check for continuity from TB1 3 through P S 45 P5 1 through P S J6 P6 9 to the socket positions 1 and 2 B Check for continuity from TB1 4 through P S J5 P5 2 through P S J6 P6 3 to P S socket positions 9 and 10 Is 12 VDC available at P S J2 13 to ground Replace mother board 15 12 VDC available at P S J2 5 to ground Try new time delay card Is approximately 40 VAC available at P S TB1 3x2 to LS Is approximately 40 VDC single phase 50 VDC 3 phase available at P S J1 14 to ground Replace mother board Try new line side voltage sensor Check 812 5 and 6 contact if testing with key switch Check exercise clock and S16 if exercising WH sah R X O XX XX OQ B XX X G X xx m s x lt x lt x KD x x x x mm Power w 79 Redistribution or publication of this document Generation by any means is strictly prohibited AWA RNIN G The following troubleshooting procedures present hazards that can resul in severe personal
23. Normal Handcrank switch on the transfer switch whichever applies to Stop 2 Disconnect the starting batteries of the generator set remove the ground lead first 3 Remove AC power to the automatic transfer switch If the instructions require otherwise use extreme caution due to the danger of shock hazard Place rubber insulative mats on dry wood platforms over metal or concrete floors when working on any electrical equipment Do not wear damp clothing par ticularly wet shoes or allow skin surfaces to be damp when handling any electrical equipment Jewelry is a good conductor of electricity and should be removed when working on the electrical equipment Do not work on this equipment when mentally or physi cally fatigued or after consuming any alcohol or drug that makes the operation of equipment safe OT2 UG 3 Power Redistribution or publication of this document Generation by any means is strictly prohibited Table of Contents TITLE PAGE Safety Precaulions Inside Front Cover Table of Contents PH 1 Iniroduction AT 2 About this Man al 646454 nec cewek Cuasi sy eee 2 Model Identification RR GV EE RAS REN a ORA E 2 Power Sentry
24. PLUGS ACTUATOR CAPSCREWS BARRIER N SPACER JUMPER WIRE SECTION A A SWITCH FRONT COVER CAPACITORS GROUND WIRE PLASTIC BARRIER 1 TORQUE SHALL 10 15 IN LBS FOR 46 32 SCREWS 2 TORQUE SHALL BE 25 30 IN LBS FOR 10 32 SCREWS 3 TORQUE SHALL 70 75 IN LBS FOR 1 4 20 SCREWS 4 TORQUE SHALL BE 10 12 FT L8S FOR 5 16 18 SCREWS FIGURE 19 TRANSFER SWITCH FRONT COVER Power Generation 36 Redistribution or publication of this document by any means is strictly prohibited 150 260 MODEL ROD END ASSEMBLY HEX HEAD CAPSCREW WITH LOCK WASHER GROUND BRUSH ACTUATOR ROD BLACK WHITE FIGURE 20 LINEAR ACTUATOR 2 Hold actuator motor in position over the switch assemblies so the lead wires are at the bottom and fit the rod assembly into the handle of the closed switch assembly 3 Secure the actuator motor to the switch assem blies using hex head capscrews 4 lock washers 4 flat washers 4 barriers 2 and spacers 4 Tighten capscrews to 70 to 75 in lbs 7 9 to 8 5 Nem 4 Connectthe black actuator lead wire to the circuit breaker and the red and white actuator lead wires to the following capacitor terminals Red Lead Wire Connectto capacitor Termi nal 2 White Lead Wire If one capacitor connect to capacitor C1 Terminal 1 If two capacitors con nect to capacitor C2 Terminal 2
25. Power _ Generation Undervoltage sensing is accomplished by sensing all voltage phases but responding only to the lowest one Thus all phases must be above the pick up point before undervoltage pickup will occur while undervoltage dropout will occur when any of the phase voltages fall below the dropout point A fixed dropout time delay 0 5 seconds occurs before the Source OK output responds to an undervoltage condition The sensor is calibrated and the undervolt age pickup and dropout points are adjusted with potentiometers see Voltage Sensor Adjustments section The pickup adjustment range is 85 to 100 of the nominal voltage The dropout adjustment range is 75 to 98 of the pickup setting Overvoltage sensing is accomplished by monitoring the peak of the combined phase voltages so that the sensor essentially responds to the highest phase The sensor is calibrated and the overvoltage limit is adjusted with potentiometers see Voltage Sensor Adjustments sec tion The overvoltage adjustment range is 10596 to 135 ofthe nominal voltage The pickup point is fixed at 596 below the overvoltage limit point and is not adjusta ble A time delay is also included which is adjustable from 0 5 to 120 seconds Over and underfrequency sensing is accomplished by sensing the source frequency and detecting when it is within a specific band The pickup bandwidth is adjusted with a potentiometer see Voltage Sensor Adjustme
26. REMOVAL AND REPLACEMENT 150 260 Amperes Disconnect both the normal and the emergency power source from the transfer switch before servic ing If a generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the set starting battery The selector switch is located on the generator set control panel on two wire start sys tems and on the transfer switch control pane on three wire start systems High voltages within the cabinet AWARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the switch assemblies tor 150 260 ampere switches 1 Removethe linear actuator as described in Linear Actuator Removal and Replacement section for 150 to 260 Ampere switches Follow steps 1 through 8 in the Removing Actuator section 2 Remove the hex head capscrews locking washers and flat washers that secure the inter lock bar to the interlock arm Figures 21 and 22 and remove the interlock bar 3 Remove the round head machine screws and mounting plate that secure the handle assembly to the switch assembly and lift off the handle assembly Figure 23 Power Generation 38 4 Disconnect the control wiring leads from the 10 11 jumper bus bars Remove the hex h
27. REVERSING CONTACTOR T1 LINE SIDE TRANSFORMER K1 RELAY COIL T2 GENERATOR SIDE TRANSFORMER K2 RELAY COIL SC 1161 FIGURE 5 RELAY CONTROL Power f 15 Redistribution or publication of this document Generation by any means is strictly prohibited K4 Retransfer Time Delay Relay The K4 Retransfer Time Delay relay see Figure 5 is used to delay transferring the load from the emer gency sidetothe normal side when the normal power source returns This allows the normal power source voltage to stabilize before the load is retransferred The time delay is adjustable from 3 to 30 minutes and begins timing on pick up At the end of the timing period the control will signal for the generator set to stop K5 Line Voltage Relay The K5 Line Voltage relay see figure 5 is used with transfer switches that have the optional time delay relays start and retransfer The K5 relay works in conjunct on with the T1 Line Sidetransformerto pro vide single or all phase lineloss sensing of the normal power source Loss of normal line voltage in any phase will drop out all relays and initiate generator set starting When the normal power source returns normal line voltage energizes the K5 relay and closes the K5 contacts This connects normali line voltage to the K4 Retransfer Time Delay which initiates load retransfer to the normal source K6 Generator Voltage Relay The K6 Generator Voltage relay is used on transfer switches that have the op
28. _ _ WASHER AND FLAT 4 18 20 LB 24 4 27 1 Nem WASHER SHOULDER SCREW AND LOCK WASHER CAPSCREW AND LOCK WASHER 3 INSULATOR LOAD STRAP SCREW 1 B INSULATOR XSC 1476 LINE STANDOFF STRAP A PLACE THIN COAT OF ELECTRICAL JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES N PLACE A THIN OF THREAD SEALANT TO THREADS OF SCREW THEN TYPICAL TERMINAL TYPICAL TERMINAL TIGHTEN TO GIVEN TORQUE IDENTIFICATION IDENTIFICATION VIEW A A VIEW B B FIGURE 40 REAR CONNECT TRANSFER SWITCH ASSEMBLY 69 Power Redistribution or publication of this document Generation by any means is strictly prohibited 400 600 AMP MODEL SPEC ARC CHUTE COVER SCHEW GROSSBAR ASSEMBLY ARC CHUTE s r prep F NOTAN lt S HET b SECTION B B XSC 1477 D 10 15 IN LB 1 1 1 7 Nem FIGURE 41 SWITCH ASSEMBLY Removing Switch Assembly Normal or Emergency 1 Remove the linear actuator as described in Linear Actuator Removal and Replacement section of this supplement Follow steps 1 through 10 in the Removing Actuator Section Remove the hex head capscrews lock washers and flat washers that secure the interlock bar to the interlock arm Figures 39 and 40 and remove the interlock bar Disconnect the control wiring from the jumper bus bars Remove th
29. bushings and jam nuts from the back of the switch assembly and save for reuse Remove the hex head capscrew and spring washer that secure the interlock arm to the switch assembly and lift off the interlock arm Remove the nuts locking washers and flat washers that secure the arc chute barrier see Figure 29 to the switch assembly and lift out the arc chute barrier arc chutes and arc chute insu lators Discard the arc chutes and arc chute insulators Remove the shoulder screws and locking washers that secure the handle assembly to the switch assembly and lift off the handle assembly see Figure 29 On front connect switches remove the hex head capscrews ring terminals spring washers and lug terminals from the switch assembly see Fig ure 29 On rear connect switches remove the hex head capscrews ring terminals spring washers and contact strap from the switch assembly see Fig ure 29 Remove the two hex head machine screws used to secure arc chute barrier locking washers flat washers and nuts from the switch assembly Save for reuse Redistribution or publication of this document by any means is strictly prohibited 400 AMP MODEL SPEC E INTERLOCK INTERLOCK 4 3 C Spo Seve I u ae 1 Sb he Tn i ips e ers Is OQ Qo 5 g e p ra e LO
30. generator set to run Control is timing out for overvoltage condition on Source 1 Overvoltage time delay is adjustable from 0 to 120 seconds factory setting is 5 seconds Source 1 OK light will stay on during timing out period Does not operate if no overvoltage sensor Source 1 voltage is available and within the voltage and frequency settings of the voltage frequency sensor Contro is timing out for retransfer to Source 1 power source At end of timing period light will go out Delay is adjustable from 0 to 32 minutes factory setting 15 15 minutes Control is timing out for transfer to Source 2 power source At end of timing period light will go out Delay is adustable from 0 to 120 seconds factory setting is 2 seconds 6 Redistribution or publication of this document by any means is strictly prohibited 6012 008 9ILVIW3HOS 1OB1NOO2 Ve JUNIJ 6 81 21 52 t e Hi 21 8 a tr AV 138 LINDYIO 3AIHG ia nut ra gt dii reg E AYTAY M by 25 m A u 4 MU ATA DAE mr YFA H33SNY3A3 A29N3003H1 35Y110A IDOS 39 L10A X0 328605 t 33unos 05435 JAYO 4v134 2 32un0 s OUS i a ea 5 2 A 5 39unos ne LINDYIO SLINDHID SAING HO1V1n593H ADVL
31. head capscrews 4 lock washers 4 and flat washers 4 Tighten capscrews to 70 to 75 in Ibs 7 9 to 8 5 Nem 3 Connectthe black actuator lead wire to the circuit breaker and the red and white actuator lead wires to the following capacitor terminals Red Lead Wire Connectto capacitor C1 Termi nal 2 White Lead Wire If one capacitor connect to capacitor C1 Terminal 1 If two capacitors con nect to capacitor C2 Terminal 2 Transfer switches for voltage ranges 190 200 208 347 380 416 and 440 4890 use two capacitors C1 and C2 wired together in series single jumper wire is placed between terminal 1 on C1 and terminal 1 on C2 4 Replace the capacitor end cap and install the capacitor in the bracket 5 Connect the around wire to the end of the actua tor Use wire ties to hold actuator lead wires in place with rest of wiring harness 6 Place red plastic switch cover in position and secure with machine screws 4 and flat washers 4 Tighten to 25 to 30 in lbs 2 8 to 3 4 torque 7 Insertthe actuator rod into the replacement actu ator motor see Figure 32 Hold the actuator ground brush up slightly to allow passage of the actuator rod Redistribution or publication of this document by any means is strictly prohibited 600 Spec E 800 1000 AMP SWITCH E a e Li b FRONT COVER 1 WIRING HARNESS PLUGS JUMPER WIRE CAPAC
32. head capscrews locking washers and flat washers that secure the inter lock bar to the interlock arm Figures 27 and 28 and remove the interlock bar Disconnect the control wiring leads from the jumper bus bars Remove the hex head capscrews ring terminals spring washers flat washers locking washers and nuts that secure the jumper bus bars see Figure 27 and 28 to the load bus Remove the hex head nuts and spring washers that secure the jumper bus bars to the switch assemblies and lift off the jumper bus bars Remove the control wiring leads from the power source terminals see Figures 27 and 28 On front connect switches loosen the lug termi nal screws and remove the power source supply wires from the lug terminals On rear connect switches remove the hex head capscrews flat washers spring washers and nuts that secure the contact strap see Figure 28 to the rear connect strap Remove the four hex head capscrews locking washers and flat washers that secure the switch assembly to the base and lift off the switch assembly Power _ Generation 48 10 11 12 13 14 Use care when removing the ACAUTION block and cross bar assembly from the base Carefully disengage the crossbar from the auxiliary switch lever to avoid cracking the switch lever Remove the hex head capscrews used to secure jumper bus bars locking washers flat washers spacer
33. injury or death Only qualified service personnel with knowledge of electricity fuels and machinery hazards should perform service procedures AWARNING improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety precautions in your generator set manuals A WARNING High voltages within the cabinet and the rear side of the cabinet door present a shock hazard that can cause severe personal injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove all power sources before removing and replacing components Section 3 Wire Starting Generator Set Doesn t Start During A Power Failure or Simulated Failure using Key Switch No Exerciser Clock Will engine crank from its own control Will engine crank if TB10 3 is grounded Check leads between generator set and transfer siwtch Will engine crank if TB1 3 is grounded A Check K11 1 and 7 contact should be closed B Check jumper on TB10 5 to 6 or operation of preheat relay K12 C Check K10 3 and 6 contact must be closed Will the engine crank if TB1 3 and 4 are jumpered r Check for continuity to ground from TB1 4 through 13 1 and 2 Is P S de energized Check for continuity from TB1 3 through P S J5 P5 1 through P S J6 P 6 9 to P S socket position 1 and 2 B Check for continuity from TB1 4 through P S J5 P5
34. is included on utility to utility or genset to genset installations It is used to indi cate when the alternate source is not within the voltage frequency limits as determined by the voltage sensor An externally mounted selector switch is used to set source priority The K5 Auto Manual Transfer relay optional is used to inhibit automatic retransfer of the transfer switch This relay is energized by an externally mounted switch Light Array series of light emitting diodes are used to indicate the various control signals Refer to Table 1 for a description of the control signals Mother Board Circuitry The mother board circuitry serves several functions that are essential for control operation A series of rectifier bridges receive the AC output from the transformer assemblies and rectify it The rectified voltage is used as a reference input for the voltage sensors a power source for the control elec tronics and a power source for the reversing contactor The circuitry for the rectifier bridges is shown in Figures 2 and 2B Figure 2 is a schematic of mother board 300 2109 Figure 2B is a schematic of mother board 300 2936 Because ihe revision ievel of the mother board in your transfer switch may not be the same as shown in Figures 2A and 2B refer to the drawings that were shipped with the switch Redistribution or publication of this document by any means is strictly prohibited i lt L
35. p Power _ Generation E Rn 31 Transfer switches for voltage ranges 347 380 416 440 480 and 480 use two capacitors C1 and C2 wired together in series A single jumper wire is placed between terminal 1 on 1 and terminal 1 on C2 the capacitor end 5 and install the capacitor s in the bracket s Connect the ground wire to the end of the actua tor Use wire ties to hold actuator lead wires in place with rest of wiring harness Place the red plastic barrier in position and secure to the switch base with machine screws 2 and flat washers 2 Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque Redistribution or publication of this document by any means is strictly prohibited 8 Check operation of transfer switch and alignment of actuator rod by manually opening and closing both the normal and emergency switch assemblies 9 Place red plastic switch cover in position and secure with machine screws 4 and flat washers 4 Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem torque Pluginthethree control wiring harness plugs J1 J2 and J3 and reconnect normal power source and emergency power source if a generator set is the emergency power source connect the nega tive battery cableto the starting battery and place operation selector switch in automatic or remote position 11 Test switch for proper operation and close cabinet 10 SWITCH ASSEMBLY
36. pole transfer switches Separate sec tions cover control description and operation and transfer switch removal and replacement Non automatic genset to genset and utility to utility OT transfer switches do not share the same control Because of this use only the Transfer Switch Assembly section for service information on these models Use normal and necessary safety precautions before starting any service procedures identify all hazards by referring to the Safety Precautions printed inside the front cover and observe all warnings and cautions within the manual Whenever troubleshooting remember the generatorset transfer switch and util ity power source are all interdependent MODEL IDENTIFICATION When it is necessary to coritact a Distributor or the factory regarding the transfer switch always supply the complete Model Spec Number and Serial Number as shown the nameplate Also give the numbers of any options that may be listed on a label below the nameplate The nameplate is located inside the cabinet door on the red plastic transfer switch cover The model number is made up of code segments that designate various features or options The following typical model number is broken down to illustrate OT C A 260 AX U 3101 L w Lh oI Power Generation Series identification Number of poles 2 pole B 3 pole 3 Application A Nonautomatic
37. reconnect normal power source and emergency power source If a generator setis the emergency power source connect the nega tive battery cable to the starting battery and place operation selector switch i in automatic or remote position 9 Test switch for proper operation and close cabinet SWITCH ASSEMBLY REMOVAL AND REPLACEMENT 40 70 100 Amperes Disconnect both the normal and the emergency power source from the transfer switch before servic ing If a generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the 28 set starting battery The selector switch is located on the generator set control panel for two wire start systems and on the transfer switch control panel for three wire start systems High voltages within the cabinet present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from the transfer switch before servicing Redistribution or publication of this document by any means is strictly prohibited The following procedures cover the remova and replacement of the switch assemblies for 40 to 100 Ampere switches Removing Switch Assembly Normal or Emergency 1 10 Remove the linear actuator as described in Linear Actuator Removal and Replacement section for 40 to 100 Ampere switches Follow steps 1 6 in the Removing Actuator sec
38. the emergency side This gives the emergency power source voltage time to stabilize before assuming the load The A11 time delay is connected in series with the K2 relay When the emergency power source becomes available the A11 time delay keeps the 2 relay de energized during the timing out period This prevents the K2 relay from signaling for the load to transfer Thelength of the delay period is determined by the value of the resistor that is connected across the timer terminals The standard delay period is fixed at 0 5 seconds T1 Line Side Transformer The T1 Line Side transformer is used to supply power and initiate control response to loss of line voltage The output voltage frm the T1 transformer is used to drive the K1 and relays The T1 transformer 5 connected so that a voltage potential is created between the transformer output terminal and line A or neutral if a single pole switch One side of each relay K1 K3 and K4 is connected to the transformer output terminal The other side of each relay is con nected to line A or the neutral conductor When used in conjunction with the K5 relay the T1 transformer provides a single or all phase control response to loss of line voltage from the normal power source Loss of normal line voltage in any phase will drop out all relays and initiate generator set starting T2 Generator Side Transformer The T2 Generator Side transformer is similiar in function to t
39. the in Ibs 7 9 to 8 5 Nem torque switch assemblies with hex head capscrews and 2 Install the hex head machine screws used to secure arc chute barrier locking washers 2 flat 16 3 Nem washers 2 and nuts in the switch assembly 12 Secure the jumper bus bars to each load bus bar base Tighten to 15 to 20 in Ibs 1 7 to 2 3 Nem using a hex head capscrew ring terminal lower torque row only spring washer and nut Tighten to 70 3 Place the handle assembly in position on the to 75 in lbs 7 9 to 8 5 Nem torque switch assembly and secure with shoulder 13 Connect the control wiring leads to the corres ponding jumper bus bar terminal Control wires are marked LOAD A B C for identification Redistribution or publication of this document by any means is strictly prohibited g Power 4 Generation 400 AMP MODEL SPEC E FLAT WASHERS MAGHINE SCREW BRACKET SIDE WITH chet Beni _ INSULATING BARRIER SWITCH LEVER IN CLOSED POSITION Se TWO SWITCH 1 ORIENTATE TERMINALS ON S3 AND S6 AS SHOWN 1 H i FIGURE 30 AUXILIARY SWITCHES 14 Install the interlock bar and secure to each inter lock arm with a hex head capscrew locking washer and flat washer Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem torque 15 Replace the linear actuator as described in Linear Actuator Removal and Replacement section for 400 A
40. the control to ignore momentary dips or rises in frequency Time Delay Module The time delay module Renters the following functions Start time delay Stop time delay Transfer time delay Hetransfer time delay If other than factory setting is desired align the slot on the potentiometer to the desired markings on the module panel See Figure 3 Range of adjustments and factory settings are as follows ADJUSTMENT FACTORY FUNCTION RANGE SETTING Start 0 6 seconds 2 seconds Transfer 0 120 seconds 2 seconds Retransfer 0 30 minutes 15 minutes Stop 0 10 minutes 5 minutes Redistribution or publication of this document by any means is strictly prohibited FI k JF Relay Control INTRODUCTION The retay control package is primarily an electrome chanical control designed for use with OT li auto matic transfer switches This is an optional control that is used where the more complex Power Sentry control is not required A loss of normal line voltage will cause a start signal to be sent to the standby generator set Adjustable start and retransfer time delays and non adjusiable stop and transfer time delays are also available All components for the relay control are mounted within a separate enclosure wiring harness with plug in connectors connects the control with the transfer switch DESCRIPTION The relay control consists of the following major assemblies K1 K2 Reversing Contactor Interposing
41. transfer switches The delay period is adjusta ble from 0 5 to 5 seconds 1 5 to 15 seconds or 5 to 50 seconds depending on the option selected The time delay is set by the factory for two seconds lf this delay is not safisfactory the timer can be adjusted using the following procedure Disconnect both the normal and the emergency power source from the transfer switch before servicing If a generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the set starting battery The selector switch is located on the generator set control pane on two wire start systems and on the transfer switch control panel on three wire start Systems Redistribution or publication of this document by any means is strictly prohibited Generation High voltages within the cabinet A WARNING present an electrical shock hazard can cause severe personal injury or death Dis connect all sources of AC power from the transfer switch before servicing 1 Open the transfer switch cabinet door 2 Turn the timer knob clockwise to increase the delay and counterclockwise to decrease the time delay see Figure 9 increments are marked on the knob 3 Close the cabinet and reconnect the normal power source and emergency power source lf a generator set is the emergency power source connect the negative battery cable to the starting battery and place operation sele
42. voltage sensors with the fre quency sensing option the source frequency must be within the limits set by the Frequency Pickup Band potentiometer Redistribution or publication of this document by any means is strictly prohibited 2 Turn the Undervoltage Pickup and Dropout 4 Turn the Cal potentiometer counterclockwise until potentiometers on the voltage sensor fully the Source OK lamps turns off clockwise 5 Slowly turn the Cal potentiometer clockwise until 3 Turn the Undervoltage calibration Cal potenti the Source OK lamp just turns on again ometer fully clockwise The Source OK lamp cor responding to source sensor being calibrated should be on Source One OK Normal source Source 2 OK Emergency source Refer to Figure 4 for lamp location If the Source OK lamp fails to come on and the voltage sensor has a overvol tage sensing option turn overvoltage Limit and Cal potentiometers fully clockwise p UNDERVOLTAGE FREQUENCY OVERVOLTAGE x 95 ao 1 0 as oT 00 MAX PICKUP DAOPOUT 7 PICKUP ud TIME iol LIMIT TIME DELAY OF NOMINAL OF PICKUP OF NOMINAL 15 SECONDS OF NOMINAL 2 MINUTES EMERGENCY SOURCE SENSOR START RETRANSFER TRANSFER TIME x DELAY 7 iG I MODULE MAX 55 30 MIN 2 MIN UNDERVOLTAGE FREQUENCY OVERVOLTAGE Qxto AO PICKUP OROPFOUT PICKUP BAND TIME DELAY TiME DELAY OF NOMINA OFFICKUP DF NOMINAL I5 SECOND
43. wire connection to lower left capscrew 6 Disengage actuator rod from switch handle and remove actuator from switch assembly 7 Remove one of the hexhead capscrews and lock washers that secure the rod end assembly to the actuator rod 8 Remove rod end assembly from actuator rod see Figure 13 and slide rod out of the actuator Replacing Actuator 1 Insertthe actuator rod into the replacement actu ator motor from the side opposite the ground brush see Figure 13 Install the rod end assem bly and tighten capscrew to 130 to 135 in Ibs 14 7 to 15 3 Nem 2 Position actuator motor on switch assemblies so the load wires are at the bottom and fit the rod assembly into the handle of the closed switch assembly Redistribution or publication of this document Generation by any means is strictly prohibited 40 70 100 MODEL F A l WIRING HARNESS PLUGS ACTUATOR CAPSCREW COVER EMERGENCY AG BG CQ ACTUATOR GROUND CONNECTION 1 TORQUE SHALL BE 15 20 IN LBS 2 TORQUE SHALL BE 25 30 IN LBS 3 TORQUE SHALL BE 130 135 IN LBS SECTION A SECTION B B FIGURE 12 TRANSFER SWITCH FRONT COVER Power 91 Redistribution or publication of this document d Ai e a Generation by any means is strictly prohibited 40 70 100 AMP MODEL ACTUATOR GROUND BRUSH ROD END ASSEMBLY HEX HEAD
44. 0 73rd Avenue Minneapolis MN 55432 1 800 888 ONAN 612 574 5000 International Use Telex 275477 Fax 612 574 8087 Onan is a registered trademark of Onan Corporation 6 Power Redistribution or publication of this document d Generation by any means is strictly prohibited
45. 1 and K2 relays and an inter locking set of relay contacts The K1 and K2 relay contacts are used to connect line voltage to the linear actuator motor If the transfer switch is connected to the Source 2 side and the Source 1 power source is available closing the K1 contacts will energize the linear actuator motor and cause the load to transfer to the Source 1 side If the transfer switch is connected to the Source 1 side and the Source 2 power source is available closing the K2 contacts wil energize the linear actuator and cause the load to transfer to the source 2 side A mechanical interlock prevents the K1 and K2 contacts from closing at the same time An electrical interlock prevents the K1 and K2 relay coils from being energized at the same time The K1 and K2 relay coils are driven by DC output voltage from the mother board rectifier bridges C1 Storage Capacitor The C1 capacitor functions as an energy storage element During power outages the C1 capacitor holds the Two Wire Run relay energized while the start time delay times out This avoids nuisance start ing during short duration power outages C12 Filter Capacitor The C12 capacitor functions as a filter capacitor to smooth out the output voltage from the mother board rectifier bridges The integrated circuit design pro vides a rectified output voltage if either power source is available Redistribution or publication of this document by any means is strictly
46. 5 Line Voltage relay and T1 Line Side transformer Energiz ing the K5 relay closes the normally open K5 relay contacts 1 set This connects the K4 Retransfer Time Delay relay K3 Start Time Delay relay and K1 Reversing Contactor relay to the T1 transformer out put terminal The other side of each relay is con nnected to the normal line side The output voltage from the T1 transformer energizesthe K4 K3 and K1 relays Energizing the K4 relay closes the normally open K4 contacts 1 set However the closed K6 contacts paral lel the contacts so that the circuitis already complete assuming that the generator set is not running Energizing the relay opens the normally closed contacts This holds the start circuit open two wire start so that the generator set does not start Energizing the K1 relay closes the normally open K1 contacts 3 sets and opens the normally closed K1 contacis 1 set Closing the normally open K1 con tacts does not complete any circuits so that no addi tional components are energized Opening the nor mally closed K1 contacts 1 set opens the circuit between the K2 relay and the emergency power source Since the generator set is not operating the K2 relay is already de energized However opening the K1 contacts provides an electrical interlock that prevents the K2 and K1 relays from energizing at the same time Normal Power Source Interrupted If any phase of the normal power source i
47. 5 approximately 30 VDC available at P S K1 1 to ground 43 Check P S K1 auxiliary switch 44 is approximately 12 VDC available at P S J2 12 to ground 45 Try new time delay board 46 Calibrate and or try new generator side voltage sensor 47 Check pins 10 and 13 in P S J4 P4 B Check for proper jumpers 5 Power 77 Redistribution or publication of this document Generation by any means is strictly prohibited A WARNING The following troubleshooting procedures present hazards that can result in severe personal injury or death Only qualified service personnel with knowledge of electricity fuels and machinery hazards should perform service procedures A WARNING improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety precautions in your generator set manuals A WARNING High voltages within the cabinet and the rear side of the cabinet door present a shock hazard that can cause severe personal injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove all power sources before removing and replacing components Section Il 3 Phase Transfer Switch Continued Generator Set Starts During a Power Failure But Transfer Doesn t Take Place Check T1 transformer 15 K2 energized Try new K1 K2 reversing contactor Is line to line voltage available at P S K12 3 to 9
48. ATOR REMOVAL AND REPLACEMENT 400 600 Amperes Spec F Disconnect both the normal and the emergency power source from the transfer switch before servicing If a generator provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the starting battery The selector switch is located on the generator set control panel for two wire start systems and on the transfer switch control for three wire start systems High voltages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the linear actuator Removing Actuator 1 Open the transfer switch cabinet door and unplug the three control wiring harness plugs J1 J2 and J3 refer to Figure 37 from the front cover 2 Loosen and remove the ET machine screws that secure the red plastic switch cover to the transfer switch and lift off cover 3 Separate the actuator lead wires from the rest of the wiring harness remove wire ties as required 4 Remove the four ET screws two on top and two on bottom from the plug bracket Do not pull bracket from transfer switch but allow to hang loose See Figure 37 5 Pry the capacitor s loose from the bracket Remove the end cap and disconnect the red and white actu a
49. CREW WASHER AND FLAT WASHER 2 ET SCREW CAPACITOR 4 T 5 16 SCREW AND LOCK WASHER y TOGGLE SWITCH 6 SCREW CD AND LOCK WASHER f ACTUATOR ROD END ASSEMBLY LINEAR ACTUATO 1 4 SCREW LOCK WASHER AND FLAT WASHER BARRIER gt A SIG o p ON Om GND PLUG BRACKET ET SCREW FLAT WASHER 1 10 15 IN LB 1 1 1 7 Nem 51 M1 2 25 30 IN LB 2 8 3 4 Nem p 3 70 75 IN LB 7 9 8 5 Nem I 4 10 12 Ft LB 13 6 16 3 Nam DETAIL A A DETAIL B B XSC 1475 FIGURE 37 TRANSFER SWITCH FRONT COVER lt Power 66 Redistribution or publication of this document Generation by any means is strictly prohibited 400 600 MODEL SPEC F 4 10 ACTUATOR MOTOR ROD END ASSEMBLY HEX HEAD CAPSCREW WITH LOCK WASHER ACTUATOR GROUND BRUSH ROD WHITE BLACK RED XSC 1474 FIGURE 38 LINEAR ACTUATOR Connect the black actuator lead wire to the circuit breaker and the red and white actuator lead wires to the following capacitor terminals White Lead Wire Connect to capacitor C1 1 for switch with one capacitor or connect to capacitor C2 2 for Switch with two capacitors Red Lead Wire Connect to capacitor C1 2 Transfer switches for voltage ranges 347 380 416 and 440 480 use two capacitors C1 and C2 wired together in series single jumper wire is placed between 1 on C1 and ter
50. IOA ONY Redistribution or publication of this document by any means 1 strictly prohibited Power _ Generation AVTIH YNY 53 AY7SH 398nC5 SUING 53 ATTSY NOB 2 lt EX ATTYA EZLX3 5 DNS 2X 3 mom 1 P t di 2 a 1 59519 3sSvH4 l lt gt lt ew ew ew ew eee dts T3 N9i153G 3553383338 1 en N Qo un Z 1331005 YOSWIS 421 300334 124 LIOA Da SERT Int a 77777777 Av 3 IML 9662 008 21LVIW3HOS 1QH INO9 42 JUNO Ec 1naln 391 10A83AD0 E JU t k iD an asa X asas asa Gas ae rom A i Syxi Q su3f4nd 45v KWISA Jte BSi5xvHISE WANA OLOY y r HO m du dem d moo A HEU 113 3538105 d 2v5 13539 40 0 EC 39Y4834RI 3 A ooo M EX E L 1 2 i 1 1 i AINS 343404 02 770341 WQSN35 39 190 JOVLIOA 93 435 t ws m m a s s Q s
51. ITORS ND ACTUATOR IRE CAPSCREWS i SPACER lt _ m ari 25 8 COVERS 1 TORQUE SHALL BE 25 30 JN LBS FOR 10 32 SCREWS 2 TORQUE SHALL BE 70 75 IN LBS FOR 1 4 20 SCREWS 3 TORQUE SHALL BE 10 12 FT LBS FOR 5 16 18 SCHEWS FIGURE 31 TRANSFER SWITCH FRONT COVER 90 Power Redistribution or publication of this document Generation by any means is strictly prohibited 600 SPEC 800 1000 MODEL ROD END ASSEMBLY HEX HEAD CAPSCREW WITH LOCK WASHER GROUND BRUSH ACTUATOR ROD BLACK WHITE FIGURE 32 LINEAR ACTUATOR 8 Secure the rod end assemblies to the actuator rod with hex head capscrews 2 and lock washers 2 Tighten capscrews to 10 40 12 ft Ibs 13 6 to 16 3 Nem torque 9 Check operation of transfer switch and alignment of actuator rod by manually opening and closing both the normal and emergency switch assemblies Plug in the three control wiring harness plugs J1 J2 and J3 and reconnect normal power source and emergency power source f a generator set is the emergency power source connect the nega tive battery cabletothe starting battery and place operation selector switch in automatic or remote position 11 Test switch for proper operation and close cabinet 10 Power _ Generation 97 SWITCH ASSEMBLY REMOVAL AND REPLACEMENT 600 Spec E 800 1000 Amperes Disconnect both th
52. M Redistribution or publication of this document by any means is strictly prohibited voltage regulator circuit receives the output from the rectifier bridges and regulates the voltage to a constant value This circuit provides power for the K3 Two Wire Run relay K4 Backup Source Failure relay K5 Auto Manual Transfer relay voltage sensor module and time delay module The circuitry for the voltage regulator is shown in Figures 2A and 2B Several relay drive circuits are used as switches to energize the K12 K1 and K2 relays reversing contactor Two Wire Startrelay and K4 Backup Source Failure relay A signal from the time delay module switches on these circuits to drive their respective relays These drive circuits are shown in Figures 2A and 2B Voltage Sensor Modules The voltage sensors are plug in modules that fit into the J1 and J3 card edge connectors on the mother board The voltage sensors monitorthe voltage sour ces single or three phase and provide an output signal Source OK when the source is within prede termined limits Depending on the options selected the sensors test for undervoltage overvoltage and under overfrequency The Source OK output signal is latched on when all of the pickup requirements for voltage and frequency are satisfied The Source OK output signal will remain on until the voltage or fre quency goes beyond the dropout limits for longer than the corresponding dropout time delay
53. ND FLAT WASHER ACTUATOR HANDLE SHOULDER SCREW AND LOCK WASHER XSC 1475 1 25 30 IN LB 2 8 3 4 Nem 2 70 75 IN LB 7 9 8 5 8 10 12 FT LB 13 6 16 3 Nem 4 18 20 FT LB 24 4 27 1 Nem N PLACE A THIN COAT OF ELECTRICAL JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES _ PLACE A THIN COAT OF THREAD SEALANT TO THREADS OF SCREW THEN TIGHTEN TO GIVEN TORQUE VIEW A A VIEW B B FIGURE 39 FRONT CONNECT TRANSFER SWITCH ASSEMBLY Power 68 Generation Redistribution or publication of this document by any means is strictly prohibited 400 600 AMP MODEL SPEC CAPSCREW AND INTERLOCK MOUNTING BASE LOCKWASHER BAR G A BARRIER OA TRANSFER SWITCH ARM INTERLOCK CAPSCREW LOCK CAPSCREW LOCK BASE ASSEMBLY WASHER AND FLAT WASHER AND FLAT WASHER WASHER a B e HT l CAPSCREW L WASHER AND FLAT WASHER s H o AND FLAT WASHER 52 55 AA Emu TRE 36 Se 5 BLOCK AND CROSSBAR ASSEMBLY AUXILIARY SWITCH JUMPER ASSEMBLY STRAP A TORQUES ACTUATOR CAPSCREW LOCK HANDLE WASHER FLAT WASHER 25 30 IN LB 2 8 3 4 Nem SPRING WASHER AND NUT g 70 75 IN LB 7 9 8 5 Nem NUT AND RING LOCK WASHER TERMINAL j 3 10 12 FT LB 13 6 16 3 CAPSCREW LOCK
54. REPLACEMENT ac to 25 to 30 in Ibs 2 8 to 3 4 Nem 400 Amperes Spec E 9 Pluginthethree control wiring harness plugs J1 Disconnect ipi ls A 42 and J3 and reconnect normal power source PONA conu Mon and emergency power source If a generator set is ing If a generator set provides standby emergency the emergency power source connect the nega power turn the operation bs iid ia and disconnect the negative battery cable from the E inti is dm ee ipd set starting battery The selector switch is located on the generator set control panel two wire start sys position tems and on the transfer switch control panel on 10 Test switch for proper operation and close three wire start systems cabinet 41 Redistribution or publication of this document Generation by any means is strictly prohibited High voltages within the cabinet present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from the transfer swilch before servicing The following procedures cover the removal and replacement of the switch assemblies for 400 Ampere Spec E switches Removing Switch Assembly Normal or Emergency 1 Remove the linear actuator as described in Linear Actuator Removal and Replacement section for 400 Ampere Spec E switches Follow steps 1 through 7 in the Removing Actuator section Remove the hex
55. Refer to the generator set Operators Manual The pre heat time delay has a range of 0 6 to 60 seconds The relay adjustment settings are marked in increments that range from 0 to 100 percent A 100 percent setting equals a 60 second delay a 50 percent setting equals a 30 second delay etc Turn the knob ciockwise to increase the delay and counterclockwise to decrease the delay Closethe cabinet door and reconnect the normal power source Connectthe negative battery cable to the starting battery and place the set operation selector switch in the automatic position Redistribution or publication of this document by any means is strictly prohibited Transfer Switch Assembly GENERAL Th s section covers the removal and replacement procedures for the transfer switch assembly There are four separate switch assemblies within the OT II line and each assembly corresponds to a particular ampere range The four ampere range groups are 40 70 100 amperes 150 260 amperes 400 amperes and 600 800 1000 amperes For servicing purposes each transfer switch assem bly can be separated into the following components e Linear Actuator e Transfer Switch e Auxiliary Switches A separate section covers the removal and replace ment procedures for each major component within a particular amp range LINEAR ACTUATOR REMOVAL AND REPLACEMENT 40 70 100 Amperes Disconnect both the normal and the emergency power source f
56. Relay K3 Start Time Delay Relay K4 Retransfer Time Delay Relay KS Line Voltage Relay K6 Generator Voltage Relay A10 Stop Time Delay A11 Transfer Time Delay T1 Line Side Transformer T2 Generator Side Transformer The sections that follow provide a general descrip tion of each component and how it functions Not all of the components described will be used in every application because of variations in the options and features selected Refer to the appropriate schematic diagram to determine the correct parts 00 for the transfer switch Fa Power Generation K1 K2 Reversing Contactor The K1 K2 reversing contactor also called interpos ing relay see Figure 5 consists of two separate relay coils designated as K1 and K2 relays and an inter locking set of relay contacts The primary function of the K1 K2 relay isto connectline voltage to the linear actuator motor If the transfer switch is connected to the emergency side and the normal power source is available closing the K1 contacts will energize the linear actuator motor and cause the load to transfer to the normal side If the transfer switch is connectd to the normal side and the emergency power source is available closing the K2 contacts will energize the linear actuator and cause the load to transfer to the emergency side The K1 K2 relay is designed so that it is not possible 14 to connect the normal and emergency power source to the linear actuator at the sa
57. Replace mother board 27 Check TA transformer 28 A Check for proper jumpers on P S B Check connections at P S K12 3 C Check pins 13 and 14 in P S and P4 Is more than 40 VDC available at P S J3 17 to ground x gt WO xXx Power Generation 81 Redistribution or publication of this document by any means is strictly prohibited A WARNING The following troubleshooting procedures present hazards that can result in severe personal injury or death Only qualified service personnel with knowledge of eleciricily fuels and machinery hazards should perform service procedures A WARNING improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safely precautions in your generator set manuals A WARNING High voltages within the cabinet and the rear side of the cabinet door present a shock hazard that I can cause severe personal injury or death Use extreme caution to avoid touching electrical contacis when the cabinet door is open Remove all power sources before removing and replacing components Section IV Single Phase Unit Continued Generator Set Starts During a Power Failure But Transter Doesn t Take Place Check diodes CR10 CR11 and CR12 on mother board 300 2109 Check diodes CR2 and CR6 on mother board 300 2936 Check T2 transformer Is approximately 30 VDC avail
58. S OF NOMINAL 2 MINUTES NORMAL SOURCE SENSOR 5 1408 2 FIGURE 3 VOLTAGE SENSORS AND TIME DELAY MODULES SOURCE 2 OK TIMING FOR STOP TRANSFER COMMAND TIMING FOR SOURCE 2 AETRANSFER COMMAND 2 RUN TIMING FOR Ov SOURCE 1 SOURCE ONE OK TIMING FOR RETRANSFER TIMING FOR TRANSFER SC 1282 FIGURE 4 CONTROL LAMPS ie rad Power 12 Redistribution or publication of this document Generation by any means is strictly prohibited 6 TheUndervoltage sensor is now calibrated If the Overvoltage sensor was adjusted in Step 3 then recalibrate it by using the Overvoltage Sensor calibration procedure After calibration reset the Pickup and Dropout potentiometers to the factory settings or to desired setting Overvoltage Sensor The optional overvoltage sensor detects when the source voltage has exceeded the overvoltage limit If other than factory setting is desired align the slot on the potentiometer to the desired markings on the module panel See Figure 3 Range of adjustments and factory settings are shown below ADJUSTMENT FACTORY FUNCTION RANGE SETTING Limit 105 to 135 110 Time Delay to 2 minutes 9 seconds The overvoltage pickup point is fixed at 5 percent below the Limit setting The adjustable dropout Time Delay allows the control to ignore momentary overshoots in voltage If necessary the Overvoltage sensor may be cali brated as follows If the Undervoltage sens
59. T LBS FOR 5 16 18 SCREWS OR NUTS 1 CONTACT STRAP i 11 1 JUMPER BUS BAR N REAR CONNECT STRAP LOAD BUS BAR FIGURE 22 REAR CONNECT TRANSFER SWITCH ASSEMBLY Power 40 Redistribution or publication of this document Generation by any means is strictly prohibited 150 260 AMP MODEL ARC CHUTE BARRIER ARC CHUTE INSULATOR ARC 4 CHUTE FRONT CONNECT YYIOZI HUEIICIIIEI VR2OIISIUII I NIrIC I T r x 1 1 1 LUG TERMINAL t I2 FT ZLJ h 1 APPLY THIN COAT JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES 2 TORQUE SHALL BE 15 20 IN LBS FOR 8 32 SCREWS CONTROL WIRING RING 3 TORQUE SHALL BE 25 30 IN LBS 10 32 SCREWS TERMINAL 4 TORQUE SHALL BE 10 12 FT LBS FOR 5 16 18 SCREWS REAR CONNECT P t CHUTE BARRIER j d j L La FIGURE 23 FRONT AND REAR CONNECT SWITCH ASSEMBLY Fd Power 41 Generation Redistribution or publication of this document by any means is strictly prohibited 12 Remove the round head machine screws locking washers and flat washers that secure the arc chute barrier see Figure 23 to the switch assem bly and lift out the arc chute barrier arc chutes fi ibs 13 6 to 16 3 Mem torque Install the interlock arm and secure with hex head machine screws 2 Tighten screws to 70 to 75 in Ibs 7 9 to 8 5 Nem torqu
60. UE SHALL BE 10 20 FT LBS FOR 3 8 16 SCREWS 7 TORQUE SHALL BE 28 32 FT LBS FOR 1 2 13 SCREWS DETAIL A FIGURE 33 FRONT CONNECT TRANSFER SWITCH ASSEMBLY 58 Power Redistribution or publication of this document Generation by any means is strictly prohibited INTERLOCK 600 SPEC E 800 1000 AMP MODEL 4 INTERLOCK BAR SHORT CAPSCREWS TAM z 2 xd _ fe a j o Stor To O E pets mo 10 erg PA n9 x Per Taza JUMPER BUS BAR C BLOCK ASSEMBLY eee 9 lt STRAP E ARC CHUTES 1 RC CHUTE Pa BARRIER Dr 4 Ad SPACERS LOAD BUS REAR CONNECT BAR STRAP 1 PLACE A THIN COAT OF ELECTRIC JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES 2 TORQUE SHALL BE 15 20 IN LBS FOR 8 32 SCREWS 3 TORQUE SHALL 25 30 IN LBS FOR 10 32 SCREWS 4 TORQUE SHALL BE 70 75 IN LBS FOR 1 4 20 SCREWS 5 APPLY THIN COAT OF GLYPTOL BETYWEEN ARC CHUTE SPACER AND ARC CHUTE PAPER BARRIER 6 TORQUE SHALL 10 12 FT LBS FOR 5 16 18 SCREWS 7 TORQUE SHALL 18 20 FT LBS 3 8 16 SCREWS SPACER oe la ee DETAILA FIGURE 34 REAR CONNECT TRANSFER SWITCH ASSEMBLY 59 lt Power d Redistribution or publication of this document ud Generation by any means is strictl
61. UTE STRAP LUG TERMINAL 2 Pri je wt fS SN N N RO ST nnn att k eo SPACER BUSING ARC CHUTE INSULATOR ARC CHUTE BARRIER CONTROL WIRING RING TERMINAL SECTION B B LL d 1 PLACE THIN COAT OF ELECTRIC JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES 2 TORQUE SHALL 15 20 IN LBS FOR 18 32 SCREWS 3 TORQUE SHALL BE 25 30 IN LBS FOR 10 32 SCREWS 4 TORQUE SHALL BE 70 75 IN LBS FOR 1 4 20 SCREWS 5 TORQUE SHALL 10 12 FT LBS FOR 5 16 18 SCREWS OR NUTS FIGURE 29 FRONT AND REAR CONNECT SWITCH ASSEMBLY Power 91 Redistribution or publication of this document Generation by any means is strictly prohibited screws 2 and locking washers 2 Install the arc chute insulators new arc chutes new and arc chute barrier and secure with nuts 2 locking washers 2 and flat washers 2 Tighten nuts to 15 to 20 in lbs 1 7 to 2 3 Nem torque Apply thread sealant to the threads of the inter lock arm capscrew Install the interlock arm to the switch assembly and secure with capscrew and spring washer Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem torque Install the hex head capscrews used to secure the jumper bus bars locking washers flat washers spacer bushings and jam nuts in the switch assembly base Tighten to 10 to 12 ft lbs 13 6 to 16 3 Nem torque Secure switch assembly
62. able at P S K2 4 to 5 15 diode across coil shorted Is approximately 30 VDC available at P S K2 4 to ground 5 approximately 40 VDC available at P S TB2 1x1 to 1x2 Is line to line voltage available at P S TB4 2 to 3 Check connections at P S K12 9 and P S K12 3 B Check pins 11 and 13 in P S J4 P4 and J3 P3 C Check switch S6 40 70 100 amp 55 above 100 amp and connection at TB2 9 Check transformer T3 Gheck pins 10 and 13 in P S J4 P4 Is approximately 24 VDC available at P S K1 2 to ground Check lead from P S K2 5 to P S 1 2 Is approximately 24 VDC available at P S K1 1 to ground Check P S K1 auxiliary switch Is approximately 12 VDC available at P S J2 12 to ground Try new time delay board Calibrate and or try new generator side voltage sensor Check pins 10 and 13 in P S J4 P4 B Check for proper jumpers on P S 4 Check T1 transformer K2 energized Try new K1 K2 reversing contactor i Power on 82 Redistribution or publication of this document Generation by any means is strictly prohibited A WARNING The following troubleshooting procedures present hazards that can result in severe personal injury or death Only qualified service personnel with knowledge of electricity fuels and machinery hazards should perform service procedures A WARNING improper operation of the generator set presents a hazard that
63. andoff insulators 10 to 12 16 13 6 to 16 3 Nem See Figure 40 12 Secure the jumper straps to the switch assembly with the capscrews lock washers and flat washers Make sure mating surfaces have a coat ing of electrical joint compound Tighten cap screws 10 to 12 ft Ib 13 6 to 16 3 Nem Secure the load straps to the jumper straps with the capscrews lock washers flat washers spring washers ring terminals and nuts Figures 39 and 40 Be sure to apply a thin coat of electrical joint compound between the current carrying surfaces Tighten 70 to 75 in Ib 7 9 to 8 5 Nem Install the actuator handle on the switch assem bly with the shoulder screws and lock washers Use a torque of 25 to 30 in 2 8 to 3 4 Connect the power source supply wires and load wires to the lug terminals front connect switches or the line and load straps rear con nect switches Tighten lug terminals to the torque value silkscreened on the transfer switch Cover Connect the control wiring leads to the corres ponding power source terminals Control wires are marked NORM A B or EMER A B C for identification Connect the control wiring leads to the corres ponding jumper strap Control wires are marked LOAD A B C for identification install the interlock bar and secure to each interlock arm with a hex head capscrew and lock washer See Figures 39 and 40 for proper torques Replace the linear a
64. any means is strictly prohibited A WARNING The following troubleshooting procedures present hazards that can result in severe personal injury or death Only qualified service personnel with knowledge of electricity fuels and machinery hazards should perform service procedures WARNING ING improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safely precautions in your generator set manuals High voltages within the cabinet and the rear side of the cabinet door present a shock hazard that A WARNING can cause severe personal injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove all power sources before removing and replacing components Section 3 Phase Transfer Switch Generator Set Starts During a Power Failure But Transfer Doesn t Take Place Is generator voltage proper on all phases Is Source 2 OK light on Is approximately 40 VDC available at P S J3 16 to ground 15 approximately 40 VAC available at P S TB2 4x1 to 4x2 13 line to line voltage available at 5 8 to 9 ls line to line voltage available at TB2 9 to 11 Check pins 13 and 14 in J3 and P3 1 approximately 40 VDC available at P S J3 15 to ground is approximately 40 VAC available at P S TB2 3x1 to 3x2 Is line to line voltage available at P S 6 to 7 Is line line voltage
65. auxiliary switch lever to avoid cracking the switch lever Remove the pan head screws that secure the left and right phase barriers and retainer barriers see Figure 17 to the switch assembly and lift out the phase barriers retainer barriers arc chutes and arc chute barriers Discard arc chutes and arc chute barriers Power i eneration 29 11 On front connect switches remove the round head machine screw locking washer ring termi nal lug terminal and U strap from the switch assembly see Figure 16 On rear connect switches remove the round head machine screw flat washers contact strap locking washer nut and U strap from the switch assembly see Figure 16 Replacing Switch Assembly 1 Applyathin coat of electric joint compound to the mating surfaces of the U strap before installing on replacement switch assembly On front connect switches install the U strap place square hole side up lug terminal ring terminal locking washer and round head machine screw on the replacement switch assembly Tighten to 28 to 32 in Ibs 3 2 to 3 6 Nem torque On rear connect switches install the U strap contact strap flat washer 1 of 2 round head machine screw flat washer 2 of 2 and nut onthe replacement switch assembly Tighten screw to 28 to 32 165 3 2 to 3 6 Nem torque Install the arc chute barriers new arc chutes new retainer barrier and left and right phase barriers and
66. available at TB2 10 to 11 Check pins 10 and 14 in J3 and P3 Is approximately 40 VDC available at P S J3 14 to ground Is approximately 40 VAC available at P S TB2 2x1 to 2x2 Is line to line voltage available at P S TB4 4 to 5 Is line to line voltage available at TB2 9 to 10 Check pins 10 and 13 in J3 and P3 8 approximately 40 VAC available at P S TB2 2x1 to GS Is there a jumper connecting TB1 5 to 6 Add jumper or check operation of a transfer inhibit circuit Check pins 17 and 18 in P S J5 and P5 Is Transfer Command light on Is Timing for Transfer light on Is 12 VDC available at P S J2 6 to ground Calibrate or try new generator side voltage sensor N OO aa ok 13 mo T N N IO mM aoa un ARON 000 4900 EL Power a Redistribution or publication of this document Generation 76 by any means is strictly prohibited A WARNING The following troubleshooting procedures present hazards that can result in severe personal injury or death Only qualified service personnel with knowledge of eleciricity fuels and machinery hazards should perform service procedures A WARNING improper operation of the generator set presents a hazard that can cause severe personal injury death Observe all safety precautions in your generator set manuals A WARNING High voltages within the cabinet and the rear side of the cabinet door present a shock hazard tha
67. between the current car rying surfaces of the contact strap and rear con nect strap see Figure 22 Secure with hex head capscrew spring washer flat washer locking washer and nut Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem torque Disconnect both the normal and the emergency power source from the transfer switch before servic ing If a generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the set starting battery The selector switch is located on the generator set control panel on two wire start sys tems and on the transfer switch control panel on three wire start systems Power 42 Generation Redistribution or publication of this document by any means is strictly prohibited 5 2788 xum High vollages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the auxiliary switch assembly tor 150 to 260 Ampere switches Removing Auxiliary Switch Assembly 1 Open the transfer switch cabinet door and unplug the three control wiring harness plugs J1 J2 amp J3 Refer to Figure 19 from the front cover 2 Loosen and remove the four machine screws with flat washers that secure the red plastic switch cover to the switch ba
68. bus bars see Figures 33 and 34 to the load bus bars 7 Remove the hex head capscrews spring washers and bushings that secure the jumper bus bars to the switch assemblies and lift off the jumper bus bars 8 Remove the control wiring leads from the power source terminals see Figures 33 and 34 9 On front connect switches loosen the lug termi nal screws and remove the power source supply wires from the lug terminals On rear coannect switches remove the hex head capscrews flat washers spring washers ring terminals and nuts that secure the contact strap see Figure 34 to the rear connect strap Power Generation 61 10 14 12 13 14 15 Remove the hex head capscrews lock washers and flat washers that secure the block assemblies see Figures 33 and 34 to the base and lift off the block assemblies note where spacers are used Remove the round head machine screws locking washers and flat washers that secure the arc chutes see Figures 33 and 34 to the block assemblies and lift out the arc chutes arc chute barriers and arc chute spacers Discard the arc chute barriers and spacers Remove the hex head capscrews spring washers and lug terminals front connect or contact straps rear connect from the block assemblies Remove the hex head capscrews lock washers and flat washers that secure the cross bar assembly to the base and lift off the cross bar assembly Use care when
69. can cause severe personal injury or death Observe all safely precautions in your generator set manuals A WARNING High voltages within the cabinet and the rear side of the cabinet door present a shock hazard that can cause severe personal injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove all power sources before removing and replacing components _ Section IV Single Phase Unit Continued Generator Set Starts During a Power Failure But Transfer Doesn t Take Place 15 line to line voltage available at P S K12 3 to 9 Check pins 11 and 13 in J3 B Check connection at TB2 9 f C Check pins 11 and 13 in P S J4 P4 D Check switch S6 40 70 100 amp S5 above 100 amp Is line to line voltage available at K12 2 to 8 Check K12 relay contacts Is line to line voltage available at linear motor black to red leads Check linear motor windings and capacitor assembly A Check pins 1 and 3 in P S J4 P4 B Check pins 1 and 3 in J3 P3 C Check motor disconnect switch S1 D Check E Check switch 53 Power Generation 83 Redistribution or publication of this document by any means is strictly prohibited Redistribution publication of this document by any means is strictly prohibited Redistribution publication of this document by any means is strictly prohibited Onon Onan Corporation 140
70. ctor switch in automatic or remote position PROGRAMMED TRANSITION TIME DELAY raf d NN Fa 1139 FIGURE 9 PROGRAMMED TRANSITION TIME DELAY BATTERY FLOAT CHARGER Battery float chargers with 2 6 or 10 amp charging capacities are available for both 12 and 24 volt batter ies The permanently connected battery floats at a constant voltage As the battery approaches the pre set full charge voltage the charging current automat ically tapers to zero This keeps the battery fully charged with no gassing and no overcharging The float voltage is set at the correct value by the factory and should not require adjustment However if the battery shows signs of being overcharged or undercharged the float voltage can be adjusted high specific gravity bubbling of electrolyte and loss water indicate a high float voltage low specific gravity indicates a low float voltage Power Generation 23 ignition of explosive battery gases A WARNING can cause severe personal injury Do not smoke or cause any spark or flame while servicing batteries change the float voltage a fully charged battery a hydrometer a small screwdriver with insulated shank and an accurate voltmeter 0 5 accuracy are needed Use the following procedures to adjust Turn the operation selector for the generator set to STOP and disconect the set starting battery The selector switch is locat
71. ctuator as described earlier in this supplement under Replacing Actuator Attempt to close both sides of thetransfer switch The interlock assembly must hold one side open so that only one side closes at a time Power _ Generation 11 14 Test switch for proper operation and cabinet AUXILIARY SWITCH REMOVAL AND REPLACEMENT 400 600 Amperes Spec F Disconnect both the normal and emergency power sources from the transfer switch before servicing If a generator set provides standby emergency power turn the operation selector switch to STOP and dis connect the negative battery cable from the set start ing battery The selector switch is located on the generator set control panel for two wire start systems and on the transfer switch for three wire start Systems High voltages within the cabinet A WARNING present an electrical shock hazard that can cause seyere personal injury or death Dis connect all sources of AC power from ihe transfer switch before servicing The following procedures cover the removal and replacement of the auxiliary switch Removing Auxiliary Switch Assembly 1 Open the transfer switch cabinet door and unplug the three control wiring harness plugs J1 J2 and J3 refer to Figure 37 from the front cover 2 Loosen and remove the four ET screws that secure the red plastic switch cover to the transfer switch and lift off the cover 3 Remove the four ET screws that secu
72. d C2 wired together in series single jumper wire is placed between terminal 1 on C1 and terminal 1 on C2 Replace the capacitor end cap s and install the capacitor s in the bracket s Connect the ground wire to the end of the actua tor Use wire ties to hold actuator lead wires in place with rest of wiring harness Check operation of transfer switch and alignment of actuator rod by manually opening and closing both the normal and emergency switch assembiies Redistribution or publication of this document by any means is strictly prohibited 400 AMP MODEL SPEC E FRONT COVER SWITCH 4 Ex F TEL WIRING S PS HARNESS PLUGS JUMPER WIRE CAPACITORS I y ni IM 2 509899 K CAPSCREWS m SPACER ONS dNs C O O 1 TORQUE SHALL BE 25 30 IN LBS FOR 10 32 SCREWS 2 TORQUE SHALL BE 70 75 IN LBS FOR 1 4 20 SCREWS 3 TORQUE SHALL BE 10 12 FT LBS FOR 5 16 18 SCREWS FIGURE 25 TRANSFER SWITCH FRONT COVER Power 46 Redistribution or publication of this document Generation by any means is strictly prohibited 400 AMP MODEL SPEC E ROD END ASSEMBLY ACTUATOR ROD BLACK WHITE HEX HEAD CAPSCREW WITH LOCK WASHER GROUND BRUSH FIGURE 26 LINEAR ACTUATOR SWITCH ASSEMBLY REMOVAL 8 Place red plastic switch cover in position and secure with machine screws 4 and flat washers AND
73. d in series with the K2 Reversing Contactor relay The other side of the K2 relay is connected to the emergency line side The A11 time delay holds the K2 relay circuit open until the transfer time delay has timed out Atthe end of the time delay the circuit closes and output voltage from transformer T2 energizes the K2 relay Energizing the K2 relay closes the normally open K2 contacts 2 sets and opens the normally closed K2 contacts 1 set Opening the normally closed K2 contacts opens the K1 relay circuit Since the normal power source is not available the K1 relay is already de energized However opening the K2 contacts provides an electrical interlock that prevents the K1 and K2 relays from energizing at the same time Closing the normally open K2 contacts connects line to line voltage from the emergency side to the linear actuator motor This energizes the linear actua tor and causes it to open the transfer switch on the normal side and close the transfer switch to the emergency side When the transfer switch closes to the emergency side the S6 auxiliary switch opens the linear actuator circuit which de energizes the linear actuator motor the T2 transformer and the K2 relay The K2 relay contacts return to their de energized position The transfer switch remains closed to the emergency side and the load is now powered by the generator set Emergency Power Source Connected to Load Under emergency power conditions the tran
74. d on the generator set control panel for two wire start sys tems and on the transfer switch control panel for three wire start systems High voltages within the cabinet AWARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from ihe transfer switch before servicing The following procedures cover the removal and replacement ofthe switch assemblies for the 400 and 600 ampere Spec F transfer switches Redistribution or publication of this document by any means is strictly prohibited 400 600 AMP MODEL SPEC F A CAPSCREW AND INTERLOCK MOUNTING BASE LOCK WASHER BAR A BARRIER TRANSFER SWITCH ARM INTERLOCK CAPSCREW LOCK BLOCK AND BASE ASSEMBLY WASHER AND FLAT CROSSBAR ASSEMBLY WASHER C pel al 1 i i ite I M 2 _ i fom SOLDERLESS 55 Co LUG ss c AUXILIARY SWITCH JUMPER ASSEMBLY STRAP 3 N CAPSCREW LOCK WASHER FLAT WASHER SPRING WASHER AND NUT RING TERMINAL ET LOCKWASHER AND FLAT WASHEH Vk a eS E g AFAN 1T MT IT CAPSCREW INSULATOR LOAD SCREW AND SPRING WASHER STANDOFF STRAP SCREW AND LOCK WASHER TYPICAL TERMINAL IDENTIFICATION TYPICAL TERMINAL IDENTIFICATION SECTION C C CAPSCREW LOCK WASHER AND FLAT WASHER SCREW LOCK WASHER A
75. d unplug the three control wiring harness plugs J1 J2 amp J3 Refer to Figure 12 from the front cover 2 Loosen and remove the four machine screws with flat washers that secure the red plastic switch cover to the switch base and lift off the cover 3 Remove the control wiring leads from the auxil iary switch terminals see Figure 18 4 Remove the round head machine screws that secure the auxiliary switch assembly bracket to the base 5 Disengage the auxiliary switch lever from the transfer switch crossbar and lift out the auxiliary switch assembly Use care when disengaging A CAUTION switch lever from crossbar to avoid cracking the switch lever Redistribution or publication of this document by any means is strictly prohibited 40 70 100 MODEL j ul MACHINE SCREW Hu ur J INSULATING a BARRIER SWITCH LEVER CLOSED POSITION AUXILIARY SWITCH LEVER BRACKET 1 ALIGN TERMINALS ON 3 AND S7 AS SHOWN NORMAL SIDE EMERGENCY SIDE LL Or x SIDE WITH TWO SWITCH TERMINALS ET FIGURE 18 AUXILIARY SWITCHES 6 Remove the round head machine screws and nuts 2 Install the auxiliary switches 4 and insulating that secure the auxiliary switches to the bracket barriers 5 in the bracket and secure with round see Figure 18 and lift out the four auxiliary head machine screws 2 and nuts 2 Note that switches insulating barriers and switch lev
76. e Install the arc chute insulators new arc chutes new and arc chute barrier and secure with machine screws 2 locking washers 2 and flat washers Tighten screws to 70 to 75 7 9 to 8 5 Nem Install the two th readed hex spacers in the back of Connect the control wiring leads to the corres ponding power source terminals Control wires are marked NORM B C or A B C for identification and arc chute insulators Discard the arc chutes 8 Apply a thin coat of electric joint compound and arc chute insulators between the current carrying surfaces of the On front connect switches remove the hex head jumper bus bars the braided strap connectors capscrews ring terminals spring washers and and load bus bars lug terminals from the switch assembly see Fig 9 Install the jumper bus bars and secure to the ure 23 X switch assemblies with hex head capscrews and spring washers Tighten to 10 to 12 ft Ibs 13 6 to On rear connect velis remove the dp pes 16 3 Nem torque capocrewe ermine T spring washers sh 10 Secure the jumper bus bars to each load bus bar dies ete Prone SWEM SS using a lead capscrew ring terminal lower row only spring washer and nut Tighten to 70 to 75 in lbs 7 9 to 8 5 Nem torque Replacing Switch Assembly 11 Connect the control wiring leads to the corres f ponding jumper bus bar terminal Control wires 1 Apply a thin coat of electric
77. e Both the Source 1 OK lamp and the Retransfer Command lamp will remain on during the timing period If the voltage returns during the 0 5 second delay the sensor will reset itself This short delay prevents the time delay module from respond ing during momentary dips in voltage The overvoltage sensor will begin timing if the source voltage rises above the dropout setting The overvol tage dropout time delay is adjustable for 0 5 to 120 seconds and is factory set for 5 seconds The Timing for Overvoltage Source 1 Source 1 OK and Retransfer Command lamp will remain on during the timing period If the voltage returns to normal during the timing period the sensor will reset itself Power The over underfrequency sensor will begin timing out if the source frequency rises above or falls below the dropout setting The frequency dropout time delay is adjustable from 0 1 to 15 seconds Both the Source 1 OK lamp and the Retransfer Command lamp will remain on during the timing out period If the frequency returns to normal during the timing out period the sensor will reset itself Start Time Delay the normal power source is still faulty after the voltage sensor has timed out all light array lamps will go out and the starttime delay will begin timing The start time delay is adjustable from O to 6 seconds and is factory set for 2 seconds All lamps will stay out while the starttime delay is timing The starttime delay prevents gen
78. e auxiliary switch assembly in position on base side with two terminals must face inward and secure bracket to base with round head machine screws Tighten 25 to 30 in Ib 2 8 to 3 4 Nem Install control wiring leads the corresponding switch terminals Leads are marked with the ter minal numbers S2 NO S5 NC S7 C etc for identification of auxiliary switch terminals FLAT WASHERS the plug bracket in position on the transfer switch base and secure with the four ET screws 4 Tighten 25 to 30 in Ib 2 8 to 3 4 Nem Place red plastic cover position and secure with the ET screws 4 Tighten 25 to 30 in Ib 2 8 to3 4 Nem Plug in the three control wiring harness plugs J1 J2 and J3 and reconnect the normal power and emergency power sources If generator set is the emergency power source connect the negative battery cable to the starting battery and place the operation selector switch in automatic or remote position Test transfer switch for proper operation and close cabinet MACHINE SCREW INSULATING n AUXILIARY SWITCH LEVER IN CLOSED POSITION W t X a w m BRACKET 1 ORIENTATE TERMINALS ON S3 AND 56 AS SHOWN SIDE WITH TWO SWITCH TERMINALS XSC 1478 FIGURE 42 AUXILIARY SWITCHES Power Generation 12 Redistribution or publication of this document by any mea
79. e normal and the emergency power source from the transfer switch before servic ing If a generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the set starting battery The selector switch is located on the generator set control panel for two wire start systems and on the transfer switch control panel for three wire start systems High voltages within the cabinet pre A WARNING sent an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing Redistribution or publication of this document by any means is strictly prohibited 600 SPEC E 800 1000 AMP MODEL INTERLOCK SHORT ene 4 ARM 3 INTERLOCK BAH 6 2 T s Ou m KOO oS H Oa D 2 D DETAILA o JUMPEH CROSS BAR E BUS BAR ASSEMBLY BLOCK ASSEMBLY CHUTE rn 5 BARRIER Du IB o LOAD BUS SPACERS BAR 1 PLACE THIN COAT OF ELECTRIC JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES 2 TORQUE SHALL BE 15 20 IN LBS FOR 8 32 SCREWS 3 TORQUE SHALL 70 75 IN LBS FOR 1 4 20 SCREWS 4 APPLY THIN COAT 010 APPROX OF GLYPTOL BETWEEN ARC CHUTE SPACER AND ARC CHUTE PAPER BARRIER ARC CHUTE 5 TORQUE SHALL 10 12 FT LBS FOR 5 16 18 SCREWS SPACER 6 TORQ
80. e round head shoulder screws and lock washers that secure the handle assembly to the switch assembly and lift off handle assembly Remove the control wiring leads from the power source terminals Figures 39 and 40 On front connect switches loosen the lug termi nal screws and remove the power supply wires from the lug terminals Then remove the solder less lugs from the switch assemblies On rear connect switches Hemove the hex head capscrews lock washers and flat washers which secure the line straps to the switch assemblies You can loosen the line strap from the insulator standoff to enable switch removal without com plete removal of the line strap if you want or you can remove the line strap completely Remove the hex head capscrews ring terminals spring washers flat washers lock washers and nuts that secure the jumper strap to the load strap Power Generation 10 8 10 11 Remove the hex head capscrews lock washers and flat washers that secure the jumper straps to the switch assemblies and lift off the jumper straps Remove the four screws lock washers and flat washers that secure the switch assembly to the base and lift off the switch assembly Use care when removing the ACAUTION block and cross bar assembly from the base Carefully disengage the crossbar from the auxiltary switch lever to avoid cracking the switch lever Remove the hex head capscrew and lock washer that
81. ead capscrews ring terminals spring washers flat washers locking washers and nuts that secure the jumper bus bars see Figures 21 and 22 to the load bus bars Remove the hex head machine screws and spring washers that secure the jumper bus bars to the switch assemblies and lift off the jumper bus bars Remove the control wiring leads from the power source terminals see Figures 21 and 22 On front connect switches loosen the lug termi nal screws and remove the power source supply wires from the lug terminals On rear connect switches remove the hex head capscrews spring washers flat washers lock washers and nuts that secure the contact strap see Figure 22 to the rear connect strap Remove the four hex head capscrews locking washers and flat washers that secure the switch assembiy to the base and lift off the switch assembly ACAUTION Use care when removing the block and cross bar assembly from the base Carefully disengage the crossbar from the auxiliary switch lever to avoid cracking the switch lever Hemove the two threaded hex spacers from the back of each switch assembly and save for reuse Remove the two round head machine screws that secure the interlock arm to the switch assembly and lift off the interlock arm Redistribution or publication of this document by any means is strictly prohibited 150 260 AMP MODEL INTERLOCK 5 4 ARM INTERLOCK BAR 5 4
82. ed on the generator set control panel on two wire start systems and on the transfer switch control panel on three wire start systems 1 Connect the fully charged battery to the genera tor set and verify charge condition with the hydrometer A fully charged lead acid battery will have a specific gravity of 1 260 at 77 F 25 C 2 Connect the voltmeter directly to the battery ter minals and measure the voltage 3 Compare the voltage reading with the value shown in Table 1 If the voltage is above or below the recommended float voltage open the cabinet door and adjust as specified in step 4 If the vol tage is correct proceed to step 5 TABLE 1 Lead Acid Batteries Battery Voltage Float Voltage 12 13 3 24 26 6 Nickel Cadmium Batteries Float Voltage Charge Per Cell 1 38 to 1 45 Example Float charge for 10 cell battery should be 13 8 to 14 5 volts Redistribution or publication of this document by any means is strictly prohibited 4 Use a small screwdriver with insulated shank to turn the adjustment potentiometer located behind charger panel see Figure 10 counter clockwiseto increase float voltage and clockwise to decrease float voltage Adjust in small steps and wait five minutes for the voltage to stabilize before making additional adjustments High voltages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Use care when making adjustments to av
83. ely tighten the lug terminals On rear connect switches apply a thin coat of electric joint compound between the current car rying suriuces of the contact strap and rear con nect strap see Figure 16 Secure with hex head machine screw spring washer flat washer lock 9 10 Secure the jumper bus bars to each load bus bar using a hex head machine screw ring terminal flat washer lock washer and nut Tighten to 25 to 30 in Ibs 2 8 to 3 4 em torque Connect the control wiring leads to the corres ponding jumper bus bar terminal Control wires are marked LOAD A B C for identification 11 Place the handle assembly in position on the washer and nut Tighten to 70 to 75 in Ibs 7 9 to switch assembly and acute ie pan head 8 5 Nem torque screws 2 locking washers 2 and flat washers Connect the control wiring leads to the corres 2 ponding power source terminals Control wires 12 Install the interlock bar and secure to each inter are marked NORM A B C or EMER A B C for lock arm with a round head machine screw lock identification mE ing washer small flat washer and large flat Apply a thin coat of electric joint compound washer Tighten to 15 to 20 in Ibs 1 7 to 2 3 Nem between the mating surfaces of the jumper bus torque bars braided strap connector and load bus bars Install the jumper bus bars and secure to the switch assemblies with hex head machine screws and spring washers Tighten to 70 to 75
84. er each switch must be assembled so the side with two terminals see Figure 18 is facing the open end of the bracket 3 Manually close the transfer switch that will be coupled to the auxiliary switch lever 4 Hold the auxiliary switch assembly in position on the base open end of bracket must face inward and check alignment of the auxiliary switch lever Replacing Auxiliary Switch Assembly When the transfer switch assembly is closed the auxiliary switch must be aligned as shown in Fig 1 Place the auxiliary switch lever in the bracket as ure 18 Move auxiliary lever as required to get shown in Figure 18 Note that the end of the lever correct alignment with the octagonal hole must engage the transfer switch cross bar when the auxiliary switch assembly is installed Power 34 Redistribution or publication of this document Generation by any means is strictly prohibited 5 Secure bracket to base using round head machine screws and tighten to 15to 20 in Ibs 1 7 to 2 3 Nem torque 6 Install control wiring leads on the corresponding switch terminals Leads are marked with the ter minal numbers S2 NO S7 NC S9 C etc for identification Refer to Figure 18 for identification of auxiliary switch terminals 7 Place red plastic switch cover in position and secure with machine screws 4 and flat washers 4 Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem torque 8 Plug in the three control wiring harness plu
85. erator set startup when a power interruption of very short duration occurs If the normal power source returns during the timing out period the start delay will reset After the start time delay has timed out a run signa will be sent to the generator set When the generator set starts the 2 Wire Run lamp will lightto indicate the control is signaling for the generator set to run This lamp will stay on as long as the control is signaling for the generator set to run Source 2 Voltage Sensor The Source 2 voltage sen sor monitors the voltage output from the generator set When the voltage rises above the pickup setting the sensor will signa that the emergency power source is available The Source 2 OK lamp will light and stay on as long as the emergency power source is within the voltage and frequency settings of the volt age sensor 10 Redistribution or publication of this document by any means is strictly prohibited Generation Transfer Time Delay The transfer delay will begin timing as soon as the voltage sensor signals that Source 2 voltage is available The transfer time delay is adjustable from to 120 seconds and is fac tory set for 2 seconds The Timing For Transfer lamp will light to indicate the transfer time delay is timing The two second delay before transferring the load to the generator is to allow the generator voltage to stabilize After the transfer time delay has timed out the con trol
86. f s m m s s 4 t LIA uw Redistribution or publication of this document by any means is strictly prohibited Power _ Generation Q Time Delay Module The time delay module plugs into the J2 card edge connector on the mother board The time delay module contains the timing circuits and associated logic that provide time delays for generator starting load transfer load retransfer and generator stop ping The Source OK output signals are received from the voltage sensors If the Source 1 OK signal is interrupted the start time delay will begin timing out The start time delay adjustable from zero to six seconds begins timing if the input signal from the Source 1 voltage sensor is interrupted If the signal returns during the timing out period the timer will reset If the signal does not return by the end of the delay period the timer will signal forthe generator set to start The purpose of the delay is to prevent genera tor set start up when power interruptions of very short duration occur The factory delay setting is for two seconds The transfer time delay adjustable from zero to two minutes begins timing as soon as the Source 2 vol tage sensorsignals that power is available At the end of the delay the timer will signal for the load to transfer to the generator set The purpose ofthe delay is to allow the generator set to stabilze before the load is applied The factory delay setting i
87. gs J1 J2 J3 and reconnect the normal power source and emergency power source If a generator set is the emergency power source connect the nega tive battery cabletothe starting battery and place operation selector switch in automatic or remote position 9 Testswitch for proper operation and close cabinet LINEAR ACTUATOR REMOVAL AND REPLACEMENT 150 260 Amperes Disconnect both the normal and the emergency power source from the transfer switch before servic ing If a generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the set starting batt ry The selector switch is located on the generator set control panel for two wire start systems and on the transfer switch control pane for three wire start systems High voltages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the linear actuator for 150 260 Ampere switches Power Generation Removing Actuator 1 Open the transfer switch cabinet door and unpiug the three control wiring harness plugs J1 J2 amp J3 Refer to Figure 19 from the front cover 2 Loosen and remove the four machine screws with flat washers that secure the red plastic switch cover to the switch ba
88. he T1 transformer except it is connected to the generator side of the control The output voltage from the T2 transformer is used to drive the K2 relay The T2 transformer is connected so that a voltage potential is created between the transformer output terminal and line A or neutral if a single pole switch One side of the K2 relay is connected to the T2 transformer output ter minal The other side of the relay is connected to line or the neutral conductor OPERATION The following sections describe the operation of the relay control This includes the following situations and the various control responses e Normal Power Source Connected to Load Normal Power Source Interrupted e Emergency Power Source Connected to Load e Normal Power Source Restored Redistribution or publication of this document by any means is strictly prohibited Figure 6 is a schematic of a typical three phase transfer switch with the start transfer retransfer and stop time delay options Refer to Figure 6 as the operational sequence of each component is des cribed Relay contact references normally open NO and normally closed NC refer to the position of the Contacts when the relay is de energized Normal Power Source Connected to Load Under normal power conditions the transfer switch will be closed to the normal side and the load will be powered by the normal power source Line to line voltage from the normal side energizes the K
89. hould perform service procedures A WARNING Proper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety precautions in your generator set manuals A WARNING High voltages within the cabinet and the rear side of the cabinet door present a shock hazard that can cause severe personal injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove all power sources before removing and replacing components Section 3 Phase Transfer Switch Generator Starts and Transfer Takes Place Whenever the Start Stop Remote Switch is Placed in Remote ls commercial voltage OK on all prasa Is Source 1 OK light on js approximately 40 VDC available at P S J1 16 to Ground Is approximately 40 VAC available at P S TB1 1 1 to 1 x 2 Is line to line voltage available at P S TB3 2 to 3 s line to line voltage available at TB2 1 to 3 Check connections 5 and 6 on J3 and P3 at the transfer switch 1 approximately 40 VDC available at P S J1 15 to ground Is approximately 40 VAC available at P S TB1 2 x 1 to 2 x 2 Is line to line voltage available at P S TB3 4 to 5 Is line to line voltage available at TB2 2 to 3 Check connections 2 and 6 on J3 and P3 at the transfer switch ls approximately 40 VDC available at P S J1 14 to ground Is approximately 40 VAC available at P S TB1 3x1 to 3x2 Is line t
90. iary switch lever from the transfer switch crossbar and lift out the auxiliary the emergency power source connect the nega switch assembly tive battery cable to the starting battery and place operation selector switch in automatic or remote Use care when disengaging position ACAUTION switch lever from crossbar to 8 Test switch for proper operation and close avoid cracking the switch lever cabinet i _ 7 Remove the round head machine screws flat washers and nuts that secure the auxiliary switches to the bracket see Figure 30 and lift out the four auxiliary switches insulating barri ers and switch lever _ 54 Power Redistribution or publication of this document Generation by any means is strictly prohibited LINEAR ACTUATOR REMOVAL AND REPLACEMENT 600 Spec E 800 1000 Amperes Disconnect both the normal and the emergency power source from the transfer switch before servic ing If a generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the set starting battery The selector switch is located on the generator set control panel for two wire start systems and on the transfer switch control panel for three wire start systems High voltages within the cabinet AWARNING present an electrical shock hazard that can cause severe personal injury or death Use extreme caution when making adjustments to avoid
91. in lbs 7 9 to 8 5 Nem torque Power 32 Redistribution or publication of this document Generation by any means is strictly prohibited 40 70 100 AMP MODEL RETAINER BARRIER LEFT PHASE BARRIER LUG TERMINAL FIGURE 17 INSULATING BARRIERS AND ARC CHUTES 13 Replace the linearactuatoras described in Linear Actuator Removal And Replacement section for 40 to 100 Ampere switches Follow steps 2 through 8 in the Replacing Actuator section 14 Test switch for proper operation and close cabinet AUXILIARY SWITCH REMOVAL AND REPLACEMENT 40 70 100 Amperes Disconnect both the normal and the emergency power source trom the transfer switch before servic ing generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the set starting battery The selector switch is located on the generator set control panel on two wire start sys tems and on the transfer switch control panel on three wire start systems High voltages within the cabinet AWARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power ihe transfer switch before servicing Power Generation 33 The following procedures cover the removal and replacement of the auxiliary switch for 40 to 100 ampere switches i Removing Auxiliary Switch Assembly 1 Open the transfer switch cabinet door an
92. ing the time of day and entering the exercise start and stop times High voltages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Use extreme caution when making adjustments to avoid touching high vollage components Refer to the circled numbers in Figure 8B when reading the following instructions e EO SC 1579 3 FIGURE 8B ELECTRONIC EXERCISER CLOCK Redistribution or publication of this document by any means is strictly prohibited To set the time of day 1 H you are performing installation and setup press the R button 9 with the tip of a ball point pen to reset all memory Do not pressthe R button if you are only changing the time of day 2 Press the clock button 1 3 Pressthe h button 3 to set the hour of the d The clock uses 24 hour military time 4 Press the m button 4 to set the minutes of the nour 5 Press the 1 7 button 5 to advance the indicator bar 13 over the desired day number Use the 1 to represent Sunday 6 Press the Pr button 8 to enter the time To set the exercise start time 1 Slide the output selector switch 16 to the center position The output selector switch has three posi tions The Off position overrides the program and causes an exercise stop The I position overrides the program and causes an exercise start The cen ter position selects program control 2 Press the O button 2 An
93. joint compound are marked LOAD A B C for identification between the mating surfaces of the switch assembly and the lug terminal front connect or 12 Place the handle assembly in position on the the switch assembly and contact strap rear switch assembly and secure with machine screws connect 2 and mounting plate 13 Install the interlock bar and secure to each inter On frontconnect switches install the lug terminal lock arm with a hex head capscrew locking and secure with hex head capscrews ring termi washer and flat washer Tighten to 70 to 75 in Ibs nal and spring washer Tighten to 10 to 12 ft Ibs 7 9 to 8 5 Nem torque 13 6 to 16 3 Nem 14 Replace the linear actuator as described in Linear Actuator Removal and Replacement section for rear connect switches install the contact 150 to 260 Ampere switches Follow steps 2 strap and secure the hex head capscrew ring through 10 in the Replacing Actuator section AR u NONE 15 Test switch for proper operation and close cabinet AUXILIARY SWITCH each switch assembly Secure switch assembly to base with hex head REMOVAL AND REPLACEMENT capscrews 4 locking washers 4 and flat 150 260 Amperes washers 4 Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem torque On front connect switches install the power source supply wires and securely tighten the lug terminals On rear connect switches apply a thin coat of electric joint compound
94. lacing Auxiliary Switch Assembly torque Insertthe actuator rod into the replacement actu ator motor see Figure 32 Hold the actuator ground brush up slightly to allow passage of the actuator rod Securethe rod end assemblies to the actuator rod with hex head capscrews 2 and lock washers 2 Tighten capscrews to 10 to 12 ft Ibs 13 6 to 1 Place the auxiliary switch lever in the bracket as 16 3 Nem torque shown in Figure 36 9 Pluginthethree control wiring harness plugs J1 2 Install the flat washer 4 insulating barriers 4 J2 J3 and reconnect the normal power source and auxiliary switches 3 in the bracket and and emergency power source Ifa generator setis secure with round head machine screws 2 and the emergency power source connect the nega nuts 2 Note that each switch must be tive battery cable to the starting battery and place assembled so the side with two terminals faces operation selector switch in automatic or remote inward see Figure 36 when the auxiliary switch position assembly is installed 10 Test switch for proper operation and close 3 Install the auxiliary switch assembly on the base cabinet side with two terminals must face inward and secure bracket to base using round head machine screws Tighten to 25 to 30 i in lbs 2 8 to 3 4 torque 64 m Power Redistribution or publication of this document by any means is strictly prohibited Generation LINEAR ACTU
95. le When replacing a transformer assembly note that the transformer input leads will be wired with a line to line or line to neutral configuration depending on pa Power Generation the voltage and phase Referto the appropriate wiring diagram for correct hook up Mother Board Assembly The mother board assembly Figure 1 is a printed circuit board that serves as a central terminal for all the input and output signals that flow through the control It also provides a mounting point for the voltage sensing andtime delay modules and the three control relays K3 K4 and K5 Connections to the mother board are made through two terminal blocks TB1 and TB2 two mating locking pin connectors J6 and J7 and three card edge connectors J1 J2 and J3 The following sections describe the function of the major elements on the mother board J1 J2 and J3 Card Edge Connectors Connectors J1 and J3 provide a mechanical electrical connection point for the voltage sensor modules Connector J1 corresponds to the Source 1 normal power source and J3 corresponds to the Source 2 emergency power source Connector J2 provides a mechani cal electrical connection point for the time delay module K3 K4 and K5 Control Relays The K3 two wire run relay responds when the control signals for the set to run De energizing the K3 relay closes a set of contacts which sends a start signal to the generator set The K4 Alternate source Failure relay
96. me time mechanical interlock prevents the K1 and K2 contacts from clos ing atthe same time An electrical interlock prevents the K1 and K2 relay coils from being energized at the same time The K1 relay is driven by line voltage from the normal side The K2 relay is driven by line voltage from the emergency side Ininstallations that do not have the optional start time delay K3 relay the K1 relay is also used to send a start signal to the generator set When the normal power source is lost the K1 relay drops out This closes a set of contacts which signals the generator set to start K3 Start Time Delay Relay The Start Time Delay relay see Figure 5 is used to send a delayed start signal to the generator set following loss of normal source power This prevents the generator set from starting when power outages of very short duration occur If normal power returns during the timing period the relay will reset The same relay is used for both two wire and three wire start systems Thetime delay is adjustable from 1 5 to 15 seconds and begins timing following drop out At the end of the timing period the control will signal for the generator set to start Redistribution or publication of this document by any means is strictly prohibited START 4 RETRANSFER n n DELAY TIME DELAY d e A11 TRANSFER TIME DELAY A10 STOP TIME DELAY K5 LINE VOLTAGE RELAY K6 GENERATOR VOLTAGE RELAY K1 K2
97. minal 1 on C2 Replace the capacitor end cap s and install the capacitor s in the brackets of the plug bracket Fig ure 36 Connect the ground wire to the end of the actua tor Use wire ties to hold actuator lead wires in place with rest of wiring harness 7 Mount the plug bracket on the transfer switch base with the four ET screws Use a torque of 25 to 30 in Ib or 2 8 to 3 4 Nem Check operation of transfer switch and alignment of actuator rod by manually opening and closing both thenormal and emergency switch assemblies Install the red plastic switch cover on the switch with the four ET screws Tighten 25 to 30 in b 2 8 to 3 4 Nem torque Plug in the three control wiring harness plugs J1 J2 and J3 and reconnect normal power and Power Generation 67 emergency power sources If a generator set is the emergency power source connect the nega tive battery cable to the starting battery and place the operation selector switch in automatic or remote position Test switch for proper operation and close cabinet 11 SWITCH ASSEMBLY REMOVAL AND REPLACEMENT 400 600 Amperes Spec F Disconnect both the normal and the emergency power sources from the transfer switch before servic ing generator set provides standby emergency power turn the operation selector switch to STOP and disconnect the negative battery cable from the Set starting battery The selector switch is locate
98. mpere switches Follow steps 2 through 9in the Replacing Actuator section 16 Test switch for proper operation and close cabinet Power Generation AUXILIARY SWITCH REMOVAL AND REPLACEMENT 400 Amperes Spec E Disconnect both the normal and emergency power source from the transfer switch before servicing if a generator set provides standby emergency power turn the operation selector switch to STOP and dis connect the negative battery cable from the set start ing battery The selector switch is located on the generator set control panel for two wire start systems andonthe transfer switch control panel for three wire start systems Redistribution or publication of this document by any means is strictly prohibited High voltages within the cabinet AWARNING present an electrical shock hazard Replacing Auxiliary Switch Assembly that can cause severe personal injury or death Dis 1 Place the auxiliary switch lever in the bracket as connect all sources of AC power from ihe transfer shown in Figure 30 swilch before servicing 2 Install the flat washers 4 insulating barriers 4 and auxiliary switches 3 in the bracket and secure with round head machine screws 2 The following procedures cover the removal and nuts 2 Note that each switch must be replacement of the linear actuator for the 400 Ampere Spec E switches assembled so the side with two terminals faces P inward see Figure 30 when the a
99. n IV Single Phase Unit Generator Set Starts During a Power Failure But Transfer Doesn t Take Place Is generator voltage proper from phase to du Is Source 2 OK light on Is approximately 40 VDC available at P S J3 16 to aand Is approximately 40 VAC available at P S TB2 4x1 to 4x2 Is line to line voltage available at P S TB4 8 to 9 Is line to line voltage available at TB2 9 to 11 Check pins 10 and 13 in 43 B Check for jumper on TB2 10 to 11 8 Is approximately 40 VDC available at P S J3 15 to ground 9 Is approximately 40 VAC available at P S 3x1 to 3x2 10 5 line to line voltage available at P S 6 to 7 11 Is line to line voltage available at TB2 9 to 10 12 Check pins 10 and 13 in J3 and P3 13 Is approximately 40 VDC available at P S J3 14 to ground 14 Is approximately 40 VAC available at P S TB2 2x1 to 2x2 15 Is line to line voltage available P S 4 to 5 16 Is line to line voltage available at TB2 9 to 10 17 Check pins 10 and 13 in J3 and P3 18 Is approximately 40 VAC available at P S TB2 2x1 to GS 19 Is there a jumper connecting TB1 5 to 6 20 Add jumper or check operation of a transfer inhibit circuit 21 Check pins 17 and 18 in 5 J5 and P5 22 Is the Transfer Command light on 23 is the Timing for Transfer light on 24 1 12 VDC available at P S J2 6 to ground 25 Calibrate or try new generator side voltage sensor 26
100. ndonthe transfer switch control panel on three wire start systems 1 Open the transfer switch cabinet door and observe the charging rate on the battery charger ammeter see Figure 10 High voltages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Use care when making adjusiments to avoid touching high voltage components 2 Turn the adjustment knob clockwise to increase ihe charge rate and counterclockwise to decrease the charge rate 3 Close the transfer switch cabinet door and place the operation selector switch in the automatic or remote position TWO TO THREE WIRE CONVERTER two to three wire converter is available for convert ingatwo wire start transfer switch to a three wire start system The converter includes a Start Disconnect relay Overcrank relay and might include a Preheat Time Delay depending on the options selected Refer to Figure 11 for the location of each component The time delays can be using the following procedures Disconnect both the normal and the emergency power source from the transfer switch before servic ing Turn the operation selector switch for the gener ator set to STOP and disconnect the negative battery cable the set starting battery The selector switch is located on the transfer switch control panel Redistribution or publication of this document by any means is strictly prohibited Generation
101. ng For Retransfer lamp will light while the retransfer time delay is timing out The 15 minute delay before transferring the load to the normal power source allows the normal line volt age to stabilize The stop time delay will begin timing as soon as the Retransfer Command lamp lights The stop time delay is adjustable from 0 to 10 minutes and is factory set for 5 minutes The Timing For Stop lamp will light while thestoptime delay is timing out The five minute delay before stopping is to allow the generator set to cool down while running at no load When the stop time delay has timed out the control will stop signal ing for the generator set to run The 2 Wire Run lamp and the Source 2 OK lamp will go out Power _ Generation ADJUSTMENTS Utility to GenSet The adjustments on the electronic modules are fac tory set and normally do not require field adjustment If desired the Pickup Dropout and Time Delay set tings may be adjusted to other than factory settings as outlined below However the calibration Cal adjustments should be changed only if the nominal voltage is significantly different than the nameplate rating or when installing a replacement sensor module Haphazard setting of the module cal A CAUTION ibration Cal adjustments will result in abnormal operation of the transfer switch Accidental actualion of the linear A WARNING motor can cause severe personal injury Disable the motor before making adjustments
102. ns is strictly prohibited Troubleshooting This troubleshooting guide asks questions that can be answered with a yes or a no The numbers in the yes and no columns direct you to the next appropriate step An X means that the step should reveal or correct the problem described Proceed to the next step if necessary All reference points in the Power Sentry control are preceded by P S For example P S 3 refers to terminal of terminal block 2 on the 1 Power Sentry control Section 3 Phase Transfer Switch Generator set starts and takes over the load whenever the Start Stop Remote switch is put in Remote Section Il 3 Phase Transfer Switch Generator set starts during a power failure but transfer doesn t take place Section 2 Wire Starting Generator set doesn t start for a power failure simulated power failure or exercise Section 3 Wire Starting Generator set doesn t start for a power failure or simulated power dailure using the key switch Section IV Single Phase Transfer Switch Generator set starts during a power failure but transfer doesn t take place Power 73 Redistribution or publication of this document Generation by any means is strictly prohibited AWARNING The following troubleshooting procedures present hazards that can result severe personal injury or death Only qualified service personnel with knowledge of electricity fuels and machinery hazards s
103. nts section The pickup adjustment range is 4 to 20 of the nominal frequency The dropout bandwidth is fixed at 5 0 wider than the pickup band The pickup and dropout bands are centered about the nominal frequency time delay is also included which is adjustable from 0 1 to 15 seconds Redistribution or publication of this document by any means is strictly prohibited Light ON Source 2 OK Timing for Stop Transfer Command Timing for Over voltage Source 2 Retransfer Command 2 Wire Run Timing for Overvoltage Source 1 Source 1 OK Timing for Retransfer Timing for Transfer Power Generation TABLE 1 Power Sentry Control Light Array indicates Source 2 voltage is available and within the voltage and frequency settings of the voltage frequency sensor Control is timing out for generator stop signal At the end of the timing period the 2 Wire Run lamp and the Timing for Stop light will go out Control is signaling for transfer to Source 2 power source The Source 2 OK lamp and the 2 Wire Run lamp will also be on Control is timing out for overvoltage condition on Source 2 Overvoltage time delay is adjustable from 0 to 120 seconds factory setting is 5 seconds Source 2 OK light will stay on during timing out period Does not operate if no overvoltage sensor Control is signaling for retransfer to Source 1 power source The Source 1 OK light will also be on Control is signaling for the
104. o line voltage available at P S TB3 6 to 7 Is line to line voltage available at TB2 1 to 2 Check connections 2 and 5 on J3 and P3 at the transfer switch Is approximately 40 VAC available at P S TB1 3x1 to LS ls approximately 40 VAC available at P S TB1 3x1 to 512 6 Check connection 15 in P S J5 and P5 Is approximately 40 VAC available at P S TB1 3x1 to S12 5 Check 812 5 and 6 contact should be closed Is approximately 40 VAC available at P S TB1 3x1 to TB1 8 Check for the following Loose or missing jumper TB1 8 to 9 if no exerciser clock B Exerciser clock in exercise mode C Switch or exercise clock contact 4 to 5 must be closed D S16 with without load for missing jumpers or bad contacts 25 3 approximately 40 VAC available at P S JB1 3x1 to TB1 7 Ooh ck amp E gt G 15 RO A CO Qo c Power 24 14 Redistribution or publication of this document Generation by any means is strictly prohibited WARNING ARNI N G The following troubleshooting procedures present hazards that can resull in severe personal injury or death Only qualified service personnel with knowledge of electricity fuels and machinery hazards should perform service procedures AWARNING improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety p
105. o wire start systems and on the transfer switch control panel for ihree wire start systems et r az 44 Redistribution or publication of this document 13eneration by any means is strictly prohibited 4 bn a Li ee 1 A ras aa gt Gs High vollages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from the transfer Switch before servicing The following procedures cover the removal and replacement of the linear actuator for the 400 Ampere Spec E switch Removing Actuator 1 Open the transfer switch cabinet door and unplug the three control wiring harness plugs J1 J2 amp J3 Refer to Figure 25 from the front cover Loosen and remove the four machine screws with flat washers that secure the red plastic switch cover to the switch base and lift off the cover Separate the actuator lead wires from the rest of the wiring harness remove wire ties as required Pry the capacitor s loose from the bracket Remove the end cap and disconnect the red and white actuator lead wires from the capacitor terminals Disconnect the black actuator lead wire from the circuit breaker and the ground wire from the end of the actuator Remove the hex head capscrews flat washers lock washers and nuts that secure the actuator to the switch assemblies see Figure 25 and lift o
106. oid touching high vollage components Jewel 7 gt Cs Va E f T7 um E J ihi pu pan E d A s j FUSE BATTERY CHARGER FIGURE 10 BATTERY CHARGER 5 When adjustments are complete close the transfer switch cabinet door 6 Disconnect the voltmeter from the battery termi nals and disconnect pe test battery from the generator set 7 Reconnect the generator set starting battery and place the operation selector switch in automatic or remote position BATTERY TRICKLE CHARGER A battery trickle charger with 300 ma charging capac ity isavailable for12 voltbatteries Thetrickle charger provides a constant rate of charge that can adjusted from 5 to 300 milliamperes as required An adjustment knob is mounted on the charger panei for setting the trickle charge rate Power ES 1093 24 The charge rate should be adjusted if the battery shows signs of being overcharged or undercharged A high specific gravity bubbling of electrolyte and loss of water indicate overcharging low specific gravity indicate undercharging Ignition of explosive battery gases A WARNING can cause severe personal injury Do not smoke or cause any spark or flame while servicing batteries Use the following procedures to adjust the charging rate Turn the operation selector switch for the generator set to STOP The selector switch is located on the generator set control panel on two wire start systems a
107. on the side of the enclosure allows the light array to be monitored during troubleshooting and testing A wiring harness with plug in connectors connects the control with the transfer switch DESCRIPTION The Power Sentry control consists of the following major components Transformer assemblies Mother board Voltage sensor modules Time delay module K12 Heversing contactor Interposing Relay C1 storage capacitor C12 filter capacitor The sections that follow provide a general descrip tion of each component and how it functions Transformer Assemblies Two sets of transformer assemblies one for each power source are mounted in the control as shown in Figure 1 Each assembly includes four transformers mounting bracket terminal block and protective cover Thetransformers step down the line voltage to approximately 40 VAC The output from the trans formers is supplied to the mother board rectifier bridges The transformer assemblies are not the same for every control even through they may appear identi cal Each transformer assembly must be used with the correct line voltage and phase or the control can be damaged when power is applied For this reason the transformer assemblies from different controls are not interchangeable unless the voltage codes are the same However all of the transformers within an assembly are interchangeable and the two trans former assemblies within the same control are inter changeab
108. or has not been calibrated do so before proceeding 1 Ensure that nominal voltage is present on all phases of the source calibrated Normal or Emergency On voltage sensors with the fre quency sensing option the source frequency must be within the limits set by the Frequency Pickup Band potentiometer 2 Turnthe overvoltage Limit and Time Delay poten tiometers fully counterciockwise 3 Turn the Overvoltage Cal potentiometer fully clockwise The Source OK lamp for the selected source should light Figure 4 4 Turn the Cal potentiometer counterclockwise until the Source OK lamp turns off 5 Slowly turn the Cal potentiometer clockwise until the Source OK lamp just turns on again After calibration reset the Overvoltage Limit and Time Delay potentiometers to the desired values Power Generation 13 Frequency Sensor The optional frequency sensor detects when the source frequency is within an acceptable band This band is centered about the nominal system frequency 50 or 60 hertz If other than factory setting is desired align the slot on the potentiometer to the desired markings on the module panel See Figure 3 Range of adjustments and factory settings are shown below ADJUSTMENT FACTORY FUNCTION RANGE SETTING Pickup Band 4 to 20 1096 Time Delay 0 to 15 Seconds 5 Seconds The dropout bandwidth is always 2 5 wider on each end than the pickup bandwidth The adjustable dropout Time Delay allows
109. over to the base and lift off the switch Cover Remove the round head machine screws that securethe plug bracketto the base Push the plug bracketto the side toallow accesstothe auxiliary switches Remove the control wiring leads from the auxil jary switch terminals see Figure 36 63 Redistribution or publication of this document by any means is strictly prohibited 6 Remove the round head machine screws that 4 Install control wiring leads on the corresponding secure the auxiliary switch assembly bracket to switch terminals Leads are marked with the ter the base minals numbers 52 0 S5 NC S7 C etc for 7 Disengage the auxiliary switch lever from the identification Refer to Figure 36 for identification transfer switch crossbar and lift out the auxiliary of auxiliary switch terminals switch assembly 5 Place the plug bracket in position on the base and secure with round head machine screws 4 ACAUTION Use care when disengaging Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque swilch lever from crossbar to 6 Place red plastic switch cover in position and avoid cracking switch fever secure with machine screws 4 and flat washers 8 Remove the round head machine screws flat 4 Tighten to 25 to 30 in lbs 2 8 to 3 4 Nem washers and nuts that secure the auxiliary switches to the bracket see Figure 36 and lift out the three auxiliary switches insulating barri ers and switch lever Rep
110. ower turn the operation selector switch to STOP and disconnect the negative battery cable from the set starting battery The selector switch is located on the generator set control panel for two wire start systems and on the transfer switch control panel for three wire start systems Redistribution or publication of this document by any means is strictly prohibited 600 800 1000 AMP MODEL NORMAL SIDE WITH TWO SWITCH TERMINALS INSULATING BARRIER SWITCH LEVER IN CLOSED POSITION 1 ORIENTATE TERMINALS ON 53 AND 56 AS SHOWN B 38157 0577 B FIGURE 36 AUXILIARY SWITCHES High voltages within the cabinet pre AWARNING sent an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from ihe transfer switch before servicing The following procedures cover the removal and replacement of the auxiliary switch assembly for 600 Spec E 800 1000 Ampere switches Removing Auxiliary Switch Assembly 1 Open the transfer switch cabinet door and unplug the three control wiring harness plugs J1 42 amp J3 Refer to Figure 31 from the front cover Power Generation 2 Remove the hex head capscrews lock washers and rod assemblies from the end of the actuator rod see Figure 32 and slide rod out of the actua tor motor Loosen and remove the four machine screws with flat washers that secure the red plastic switch c
111. programs can be repeated each day Power 22 The word Full appears the display when the memory is full If the button 2 is pressed and no program is to be entered press the Ch button 6 and then the Pr button B to get out of the program mode To check the programs 1 Press the Ch button 6 An I 12 and an Rl 15 are displayed 2 Press the Ch button 6 again The start and stop information for the first program is displayed 3 Continued pressing of the Ch button 6 causes the display to sequence through all of the programs in memory If ten programs have been entered the word Full appears after the ten program display 4 Press the Pr button 8 to return to the time of day display To change edit a program 1 Pressthe Ch button 6 until the program you wantto change appears in the display window 2 Press the button 2 to select start or stop time 3 Press the h 3 m 4 or 1 7 5 and Q 7 buttons to change the hour minute or day 4 Press the Pr button 8 to enter the edited program and return to the time of day display To erase clear a program 1 Press the Ch button 6 until the program to be erased is displayed 2 Pressthe C button 10 with thetip of a ball point pen to clear the program 3 Press the Pr button 8 to return to the time of day display PROGRAMMED TRANSITION Three programmed transition time delays are available with OT Il
112. prohibited OPERATION The following section covers the operation of the Power Sentry control in a utility to genset installa tion Source 1 is designated as the normal power source and Source 2 is designated as the emergency power source The following situations and control responses are described Normal Power Source Connected to Load Normal Power Source Interrupted Emergency Power Source Connected to Load Normal Power Source Restored Some of the control commands can be verified by observing the mother board light array Normal Power Source Connected to Load The Source 1 OK lamp will be on to indicate that the normal power source is within the voltage and fre quency settings of the voltage sensor The Retransfer Command lamp will also be on to indicate that the control is signaling forthe load to be connected to the normal power source retransfer No other light array lamps will be on Normal Power Source Interrupted An interruption in power can be defined as not only the complet loss of power but also as any situation where the voltage or frequency are outside the set tings of the voltage sensor The voltage sensor will respond to all power interruptions by blocking the Source 1 OK signal Source 1 Voltage Sensor The undervoltage sensor will begin timing if the source fails or if the voltage falis below the drop out setting The undervoltage dropout time delay is factory set for 0 5 seconds and is not adjustabl
113. re the plug bracket two on top and two on bottom see Figure 37 and move plug bracketto the left The bracket is still connected to the transfer switch by wires from the transfer switch 4 Remove the control wiring leads from the auxiliary switch terminals see Figure 42 5 Remove the round head machine screws that secure the auxiliary switch assembly bracket to the base 6 Disengage the auxiliary switch lever from the transfer switch crossbar and lift out the auxiliary switch assembly have transfer switch closed to side you are removing auxiliary switch assembly Use care when disengaging ACAUTION switch fever from crossbar to avoid cracking the switch lever 7 Remove the round head machine screws flat washers and nutsthat secure the auxiliary switches to the bracket see Figure 42 and lift out the four auxiliary switches insulating barriers and switch lever Redistribution or publication of this document by any means is strictly prohibited Replacing Auxiliary Switch Assembly 1 2 400 600 AMP MODELS SPEC F Place the auxiliary switch lever in the bracket as shown in Figure 42 install the flat washers 4 insulating barriers 4 and auxiliary switches 3 in the bracket and secure with round head machine screws 2 and nuts 2 Note that each switch must be assembled so the side with two terminals faces inward see Figure 42 when the auxiliary switch assembly is installed Hold th
114. recautions in your generator set manuals A WARNING High vollages within the cabinet and the rear side of the cabinet door present a shock hazard that can cause severe personal injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove all power sources before removing and replacing components Section I 3 Phase Transfer Switch Continued Generator Starts and Transfer Takes Place Whenever the Start Stop Remote Switch is Placed in Remote Check for loose or missing jumper TB1 7 to 8 Check pin 16 in P S J5 and 5 Replace mother board Check T1 transformer Check pins 5 and 6 in P S J4 and P4 Check T2 transformer Check pins 2 and 6 in P S J4 and P4 check jumpers on P S TB3 Check T3 transformer gt x x x x gt x x gt x X gt x gt x gt x gt x x gt x gt Check the following A Pins 2 and 5 in P S J4 and P4 B Connection at K12 1 C Jumpers on P S TB3 Is approximately 40 VDC single phase or 50 VDC three phase available at P S J1 17 to ground Check diodes CR7 CR8 and CR9 on mother board 300 2109 Check diodes CR13 CR14 and CR17 on mother board 300 2936 Is 12 VDC available at P S J1 9 to ground Calibrate or replace the source one voltage sensor 15 12 VDC available at P S J1 3 to ground Try new time delay card 2 lt XX Power w 15 Redistribution or publication of this document Generation by
115. removing the A CAUTION block and cross bar assembly from the base Carefully disengage the crossbar from the auxiliary switch lever to avoid cracking ihe switch lever Hemove the shoulder screws and lock washers that secure the handle assembly to the cross bar assembly and lift off the handle assembly see Figure 24 Remove the two round head machine screws that secure the interlock arm to the cross bar assem bly and lift off the interlock arm Replacing Switch Assembly Normal or Emergency 1 Install the interlock arm on the cross bar assem bly and secure with round head machine screws 2 Tighten screws to 15 to 20 in Ibs 1 7 to 2 3 Nemo torque Place the handle assembly in position on the switch assembly and secure with shoulder screws 2 and lock washers 2 Secure cross bar assembly to base with hex head capscrews 4 locking washers 4 and flat washers 4 Tighten to 70 to 75 in lbs 7 9 to 8 5 torque Redistribution or publication of this document by any means is strictly prohibited 4 Apply a thin coat of insulating varnish such as 10 11 12 Glyptal 1201 or Dolf ER41 between arc chute spacer and arc chute barrier Place the arc chute spacers 2 arc chute barrier and arc chute in posi tion on each block assembly and secure with round head machine screws 2 lock washers 2 and flat washers 2 Tighten to 15 to 20 in Ibs 1 7 to 2 3 Nem torque
116. rom the transfer switch before servic ing If a generator set provides standby emergency power turn the operation selector switch to STOP and disconect the negative battery cable from the set starting battery The selector switch is located on the generator set control panel on two wire start systems and on the transfer switch control panel on three wire start systems High voltages within the cabinet A WARNING present an electrical shock hazard that can cause severe personal injury or death Dis connect all sources of AC power from ihe transfer switch before servicing The following procedures cover the removal and replacement of the linear actuator for 40 to 100 Ampere switches Power 20 Removing Actuator 1 Open the transfer switch cabinet door and unplug the three control wiring harness plugs J1 J2 amp J3 Refer to Figure 12 from the front cover 2 Loosen and remove the four machine screws with flat washers that secure the red plastic switch cover to the switch base and lift off the cover 3 Separate the actuator lead wires from the rest of the wiring harness remove wire ties as required 4 Remove the red and white actuator leads from the capacitor and the black lead from circuit breaker Note the lead connections tothe capacitor terminals 5 Remove the socket head capscrews flat washers lock washers and nuts that secure the actuator to the switch assemblies see Figure 12 Note the ground
117. s for two seconds When the Source 1 power source returns and Source OK signals are received from both voltage sensors the time delay module will respond to the preferred source In utility to generator installations Source 1 normal is recognized as the preferred source In utility to utility or generator to generator installations the preferred source is selected by set ting an externally mounted selector switch The retransfer time delay adjustable from zero to thirty two minutes beginstiming as soonasthe input signal from the Source 1 voltage sensor returns At the end of the delay the timer wil signal for the load to transfer to the normal source The purpose of the delay is to allow the normal power source to stabilize before theload is applied The factory delay setting is for fifteen minutes Power Generation The stop time delay adjustable from zero to eight minutes begins timing as soon as the retransfer timer signals for the load to transfer to the normal source At the end of the delay the timer will signal for the generator set to stop The purpose of the delay is to allow the generator set to cool while running at no load The factory delay setting is for five minutes Hefer to the Time Delay Adjustments section for the time delay adjustment procedures K12 Reversing Contactor The K12 reversing contactor also called interposing relay see Figure 1 consists of two separate relay coils designated as K
118. s inter rupted either the K5 Line Voltage relay or the T1 Line Side transformer will de energize When this happens the output voltage from the T1 transformer immediately terminates causing the K4 Retransfer Time Delay K3 Start Time Delay relay and K1 Reversing Contactor relay to de energize Both the K4 and K1 relay contacts immediately return to their de energized positions However the K3 relay holds the normaily closed K3 contacts open until the start time delay has timed out Atthe end of the time delay the contacts close and a start signal is sent to the generator set Power _ Generation 17 When the generator set starts it begins to supply line voltage to the emergency side of the transfer switch However since the load is still connected to the nor mal side line voltage from the generator is not supp lied to the load Line to line voltage from the emer gency side energizes the K6 Generator Voltage relay and the T2 Generator Side transformer Energizing the K6 relay closes the normally open K6 contacts one set and opens the normally closed K6 contacts one set Opening the normally closed K6 contacts prevents the load from immediately transterring to the normal side when the normal power source returns Retransfer will not occur until the Retransfer Time Delay relay has timed out Closing the normally open K6 contacts connects the 12 transformer output terminal to the A11 Transfer Time Delay which is wire
119. se and lift off the COVer 3 Remove the screws and flat washers that secure the red plastic barrier to the switch base see Figure 19 and lift out the barrier 4 Separate the actuator lead wires from the rest of the wiring harness remove wire ties as required 5 Pry the capacitor s loose from the bracket Remove the end cap and disconnect the red and white actuator lead wires from the capacitor terminals 6 Disconnect the black actuator lead wire from the circuit breaker and disconnect the ground wire from the end of the actuator 7 Remove the hex head capscrews flat washers and lock washers that secure the actuator to the switch assemblies see Figure 19 and lift out the spacers 4 and barriers 2 8 Disengage actuator rod from switch handle and remove actuator from switch assembly 9 Remove one of the hex head capscrews and lock washers that secure the rod end assembly to the end of the actuator rod 10 Remove rod end assembly from actuator rod see Figure 20 and slide rod out of the actuator motor Replacing Actuator 1 Insertthe actuator rod into the replacement actu ator motor see Figure 20 Hold the actuator ground brush up slightly to allow passage of the actuator rod install the rod end assembly and tighten capscrew to 10 to 12 ft lbs 13 6 to 16 3 Nem Redistribution or publication of this document by any means is strictly prohibited 150 260 MODEL 24 WIRING HARNESS
120. se and lift off the cover 3 Remove the control wiring leads from the auxil iary switch terminals see Figure 24 4 Remove the round head machine screws that secure the auxiliary switch assembly bracket to the base 5 Disengage the auxiliary switch lever from the transfer switch crossbar and lift out the auxiliary switch assembly Use care when disengaging ACAUTION switch lever from crossbar to avoid cracking the switch lever 6 Remove the round head machine screws and nuts that secure the auxiliary switches to the bracket see Figure 24 and lift out the three auxiliary switches insulating barriers and switch lever Power Generation 43 Replacing Auxiliary Switch Assembly Place the auxiliary switch lever in the bracket as shown in Figure 24 Instali the flat washers 4 insulating barriers 4 and auxiliary switches 3 in the bracket and secure with round head machine screws 2 and nuts 2 Note that each switch must be assembled so the side with two terminals faces inward see Figure 24 when the auxiliary switch assembly is installed on the base Hold the auxiliary switch assembly in position on base side with two terminals must face inward and secure bracket to base using round head machine screws Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque Install control wiring leads on the corresponding switch terminals Leads are marked with the ter minal numbers S2 NO 55
121. secure to switch assembly with pan head screws 2 Hold switch assembly in position on base and check the alignment of the auxiliary switch lever When the switch assembly is closed the auxiliary switch lever must be aligned vertically as shown in Figures 14 and 15 Move auxiliary switch lever as required to get correct alignment Secure switch assembly to base with round head machine screws 2 locking washers 2 and flat washers 2 Tighten screw to 25 to 30 in Ibs 2 8 to 3 4 Nem Redistribution or publication of this document by any means is strictly prohibited 40 70 100 AMP MODEL INTERLOCK BAR HANDLE 2 ASSEMBLY JUMPER BUS LOAD BAR BUS BAR 1 2 j gz rr ss 4 ZZ Li 4 SECTION B B VIEW A A JUMPER BUS BAR LOAD BUS AUXILIARY SWITCH LEVER POSITION WHEN TRANSFER SWITCH IS CLOSED 1 PLACE THIN COAT 010 APPROX OF ELECTRIC JOINT COMPOUND VIEW D D BETWEEN CURRENT CARRYING SURFACES 2 TORQUE TO 25 30 IN LBS MAIN CONTACTS CLOSED 3 TORQUE TO 15 20 IN LBS 4 TORQUE TO 70 75 IN LBS 5 AUXILIARY SWITCH LEVER MUST TURN FREELY WITH OPERATION OF TRANSFER SWITCH FIGURE 14 FRONT CONNECT TRANSFER SWITCH ASSEMBLY Power 30 Redistribution or publication of this document Generation by any means is strictly prohibited 40 70 100 MODEL JUMPER BUS 2 3 INTERLOCK BAR BAH 4 1 2 1
122. secures the interlock arm assembly to the switch Remove the four screws and arc chute cover from the switch assembly Figure 41 Then remove the arc chutes Replacing Switch Assembly Normal or Emergency 1 2 Install the arc chutes in the switch assembly put on the arc chute cover and secure with the pan head screws Tighten 10 to 15 in ib 1 1 to 1 7 Nem Apply thread sealant to the threads of the interlock arm capscrews Mount the interlock arm on the switch assembly using torques as shown in Figure 39 or 40 Redistribution or publication of this document by any means is strictly prohibited 3 Install the switch assembly on the transfer switch 10 11 12 1 base with the screws lock washers and flat washers carefully engaging the auxiliary switch lever Tighten to a torque of 70 to 75 in Ib 7 9 to 8 5 Nem Apply a thin coat of electrical joint compound between the mating surfaces of the switch assembly and the lug terminals front connect or the switch assembiy and line straps and load straps rear connect On front connect switches install the lug terminal with the round head screw and lock washer Tighten to a torque of 70 to 75 in Ib 7 9 to 8 5 Nem On rear connect switches mountthe line strap with the capscrews lock washers and flat washers Tighten 70 to 75 in Ib 7 9 to 8 5 Nem also tighten capscrew lock washer and flat washers which secure line straps to st
123. ster switch will be closed to the emergency side and the load will be powered by the generator set Line to line voltage from the emergency side energizes the K6 Generator Voltage relay and opens the normally closed K6 contacts Holding the normally closed K6 contacts open prevents the load from immediately retransferring to the normal side when the normal power source returns Redistribution or publication of this document by any means is strictly prohibited NORMAL A B TWO WIRE START fBi TBI ant JUMPER REMOVED B l GNO FOR 3 wiRE START TRANSFER SWITCH INTERLOCK E LI ODE 4 A C 7 EMERGENCY FIGURE 6 TYPICAL RELAY CONTROL SCHEMATIC g Power 18 Redistribution or publication of this document Generation by any means is strictly prohibited vium Normal Power Source Restored When the normal power source returns line to line voltage from the normal side energizes the K5 Line Voltage relay and T1 Line Side transformer Energiz ing the K5 relay closes the normally open K5 relay contacts 1 set This connects the K4 Retransfer Time Delay relay to the T1 transformer output termi nal The other side of the K4 relay is connected to the normali line side Note that the K1 Reversing Contactor relay and Stop Time Delay relay are not connected to the T1 transformer output terminal when K5 is energized This is because the K6 relay energized by the emer gency power source
124. t can cause severe personal injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door is open Remove all power sources before removing and replacing components Section 3 Phase Transfer Switch Continued Generator Set Starts During a Power Failure But Transfer Doesn t Take Place Replace mother board 27 Check T4 transformer 28 Check for proper jumpers on B Check connection at P S K12 3 C Check p ns 13 and 14 in P S J4 and P4 29 5 more than 40 VDC available at 5 J3 17 to ground 30 Check diodes CR10 CH11 and CR12 on mother board 300 2109 Check diodes CR2 CR3 and CR6 on mother board 300 2926 31 Check T2 transformer 32 Is approximately 30 VDC available at P S K2 4 to 5 33 15 the diode across the K2 coil shorted 34 Is approximately 30 VDC available at P S K2 4 to ground 35 ls approximately 40 VAC available at P S TB2 1x1 to 1x2 36 Is line to line voltage available at P S TB4 2 to 3 37 Check connections at P S K12 9 and P S K12 3 B Check pins 11 and 13 in J4 P4 and J3 P3 C Check switch S6 40 70 100 amp S5 above 100 amp and connection at TB2 9 38 Check transformer T3 39 A Check pins 10 and 14 in P S J4 P4 B Check for proper jumpers on P S TB4 40 15 approximately 30 VDC available at 5 K1 2 to ground 41 Check lead from P S K2 5 to P S K1 2 42 1
125. tion Remove the round head machine screws locking washers and flat washers that secure the inter lock bar to the interlock arms see Figures 14 and 15 and remove the interlock bar Remove the pan head screws 2 locking washers and flat washers that secure the handle assembly to the switch assembly and lift off the handle assembly see Figures 14 and 15 Disconnect the control wiring leads from the jumper bus bars Remove the hex head machine screws ring ter minals flat washers lock washers and nuts that secure the iumper bus bars see Figures 14 and 15 to the load bus bars Remove the hex head machine screws and spring washers that secure the jumper bus bars to the switch assemblies and lift off the jumper bus bars Remove the control wiring leads from the power source terminals see Figure 16 On front connect switches loosen the lug termi nal screws and remove the power source supply wires from the lug terminals On rear connect switches remove hex head capscrews spring washers flat washers lock washers and nuts that secure the contact straps see Figure 16 to the rear connect straps Remove ihe two round head machine screws locking washers and flat washers that secure the switch assembly to the base and lift off the switch assembly Use care when removing the ACAUTION block and cross bar assembly from the base Carefully disengage the crossbar from the
126. tional time delay relays start and retransfer Line voltage from the emer gency power source energizes the K6 relay This closes a set of contacts and initates transfer of the load to the emergency side If the emergency source fails the K6 relay also pro vides for immediate retransfer of the load to the nor mal side when the normal power source returns 1 oss of emergency source power de energizes the K6 relay and closes a set of contacts that bypass the K4 Transfer Time Delay This allows the load to retransfer to the normal side as soon as the norma power source returns without waiting for the K4 relay to time out A10 Stop Time Delay The A10 Stop Time Delay is a solid state device that is used to delay generator set stopping after the load has transferred to the normal power source This gives the generator set time to cool while running at no load The A10 time delay is connected in series with the K3 relay When the load is retransferred the A10 time delay keeps the relay de energized dur ing the timing out period This prevents the K3 relay from sending a stop signal to ihe generator set The length of the delay period is determined by the value of the resistor that is connected across the timer terminals The standard delay period is fixed at five minutes FA Power d Generation 18 11 Transfer Time Delay The A11 Transfer Time Delay is a solid state device that is used to delay the load from transfering to
127. to base with hex head capscrews 4 locking washers 4 and flat washers 4 Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem torque 92 Replacing Switch Assembly 8 On front connect switches install the power Normal or Emergency source supply wires and securely tighten the lug terminals On rear connect switches apply a thin coat of electric joint compound between the cur 1 Apply a thin coat of electric joint compound rent carrying surfaces of the contact strap and between the mating surfaces of the switch rear connect strap see Figure 28 Secure with assembly and the lug terminal front connect or hex head capscrew spring washer flat washer the switch assembly and contact strap rear locking washer and nut Tighten to 70 to 75 in Ibs connect 7 9 to 8 5 Nem torque 9 Connect the control wiring leads to the corres On front connect switches install the lug terminal ponding power source terminals Control wires and secure with the hex head capscrews ring are marked NORM A B C or EMER A B C for terminal and spring washer Tighten to 70 to 75 identification in Ibs 7 9 to 8 5 Nem torque 10 Apply a thin coat of electric joint compound between the current carrying surfaces of the On rear connect switches install the contact jumper bus bars the braided strap connectors strap and secure with hex head capscrew ring and load bus bars terminal and spring washer Tighten to 70 to 75 11 Install the jumper bus bars and secure to
128. tor lead wires from the capacitor terminals 6 Disconnect the black actuator lead from the circuit breaker and the ground wire from the end of the actuator 7 Removethe hex head capscrews flat washers lock washers and nuts that secure the actuator to the switch assemblies see Figure 37 8 Disengage the actuator rod from the switch handle and remove actuator from switch assembly 9 Remove one of the hex head capscrews and lock washers that secure the rod end assemblies to the end of the actuator rod 10 Remove rod end assembly Figure 38 and slide actuator rod out of the actuator motor Replacing Actuator 1 Insertthe actuator rod into the replacement actuator motor see Figure 38 Hold the actuator ground brush up slightly to allow passage of the actuator rod install the rod end assembly and tighten caps crew 10 to 12 ft Ib 13 6 to 16 3 Nem 2 Hold actuator motor in position over the switch assemblies so the lead wires are atthe bottom and fit the rod assembly into the handle of the closed switch assembly 3 Secure the actuator motor to the switch assemblies using hex head capscrews 4 lock washers 4 flat washers 4 and spacers 4 Tighten capscrews 70 to 75 in Ib 7 9 to 8 5 Nem d Power 85 Redistribution or publication of this document gt Generation by any means is strictly prohibited nm 400 600 AMP MODEL SPEC F LOAD SCREW AND LOCK 2 ET S
129. touching high voltage components The following procedures cover the removal and replacement of the linear actuator for 600 Spec E 800 1000 Ampere switches Removing Actuator 1 Open the transfer switch cabinet door and unplug the three control wiring harness plugs J1 J2 amp J3 Refer to Figure 31 from the front cover 2 Remove the hex head capscrews lock washers and rod assemblies from the end of the actuator rod see Figure 32 and slide rod out of the actua tor motor 3 Loosen and remove the four machine screws with flat washers that secure the red plastic Switch cover to the switch base and lift off the switch cover 4 Separate the actuator lead wires from the rest of the wiring harness remove wire ties as required 5 Pry the capacitor s loose from the bracket Remove the end cap and disconnect the red and white actuator lead wires from the capacitor terminals 6 Disconnect the black actuator lead wire from the circuit breaker and the ground wire from the end ot the actuator Generation gra Power 05 7 Remove the hex head capscrews lock washers and flat washers that secure the actuator to the switch assemblies see Figure 31 and lift outthe spacers 4 and actuator motor Replacing Actuator 1 Hold actuator motor and spacers 4 in position over the switch assemblies with the lead wires at the bottom 2 Secure the actuator motor to the switch assem blies using hex
130. ut the spacers 4 and barriers 2 Disengage actuator rod from switch handle and remove actuator from switch assembly Remove one of the hex head capscrews and lock washer that secure the rod end assemblies to the end of the actuator rod Remove rod end assembly see Figure 26 and slide actuator rod out of the actuator motor Power Generation 43 Replacing Actuator 1 Insert the actuator rod into the replacement actu ator motor see Figure 26 Hold the actuator ground brush up slightly to allow passage of the actuator rod Install the rod end assembly and tighten capscrew to 10 to 12 ft lbs 13 6 to 16 3 Nem Hold actuator motor in position over the switch assemblies so the lead wires are at the bottom and fit the rod assembly into the handle of the closed switch assembly Secure the actuator motor to the switch assem blies using hex head capscrews 4 lock washers 4 flat washers 4 barriers 2 and spacers 4 Tighten capscrews to 70 to 75 in bs 7 9 8 5 Nem Connectthe black actuator lead wire to the circuit breaker and the red and white actuator lead wires to the following capacitor terminals Red Lead Wire Connect to capacitor C1 Terminal 2 White Lead Wire If one capacitor connect to capacitor C1 Terminal 1 If two capacitors con nect to capacitor C2 Terminal 2 Transfer switches for voltage ranges 347 380 418 and 440 480 use two capacitors C1 an
131. uxiliary switch assembly is installed Removing Auxiliary Switch Assembly 3 Hold the auxiliary switch assembly in position on base side with two terminals must face inward 1 Openthe transfer switch cabinetdoorandunplug and Los bracket to base with round inda s IO Figure pi J2 amp J3 Ly ak Tighten to 25 to 30 in Ibs 2 8 to 7 4 Nem torque 2 UR f is hers et four gros 4 Install control wiring leads on the corresponding wi at washers that Secure the red plastic switch terminals Leads are marked with the ter switch cover to the switch base and lift off the minal numbers S2 N0 S5 NC 7 C etc for Cover identification Referto Figure 30 for identification 3 Remove the round head machine screws that of auxiliary switch terminals secure the plug bracketto the base Push the plug 5 Place the plug bracket in position on the base and bracketto the side to allow access to the auxiliary secure with round head machine screws 4 switches Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque 4 Remove the control wiring leads from the auxil 6 Place red plastic switch cover in position and jary switch terminals see Figure 30 secure with machine screws 4 and flat washers 5 Remove the round head machine screws that 4 Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem secure the auxiliary switch assembly bracket to torque the base i 7 M inthethree control Md plis plugs J1 t r OW rce 6 Disengage the auxil
132. will signal for the load to transfer to the emer gency source The Transfer Command lamp will light and stay on as long as the control is signaling for transfer Emergency Power Source Connected to Load The Source 2 OK lamp will be on to indicate that the emergency power source is within the voltage and frequency settings of the voltage sensor The Transfer Command lamp will be on to indicate the control is signaling for the load to transfer to the emergency power source The 2 wire Run lamp will be on to indicate the control is signaling for the gen erator set to run Normal Power Source Returns Thetime delay module is programmed to identify the normal power source as the preferred power source The return of normal power will initiate several con trol responses that will eventually cause the load to retransfer to the normal side Source 1 Voltage Sensor The Source 1 voltage sen sor monitors the normal power source When the voltage and frequency rise abovethe pickup settings the sensor will signal that Source 1 voltage is avail able The Source 1 OK lamp will light and stay on as long as the normal source voltage is within the volt age and frequency settings of the voltage sensor Retransfer Time Delay The retransfer time delay will begin timing as soon as the voltage sensor signals that Source 1 voltage is available The retransfer time delay is adjustable from 0 to 30 minutes and is factory set for 15 minutes The Timi
133. y prohibited 600 Spec E 800 1000 MODEL 1 PLACE THIN COAT OF ELECTRIC JOINT COMPOUND BETWEEN CURRENT CARRYING SURFACES 2 TORQUE SHALL BE 28 33 FT LBS FOR 1 2 13 SCREW e 7 SHOULDER SCREW A Ne CROSS BAR ASSEMBLY LUG TERMINAL ARC CHUTE BARRIER i FRONT CONNECT BLOCK ASSEMBLY REAR CONNECT BLOCK ASSEMBLY FIGURE 35 CROSS BAR ASSEMBLY AND BLOCK ASSEMBLIES ea 60 Power Redistribution or publication of this document Generation by any means is strictly prohibited The following procedures cover the removal and replacement of the switch assemblies for 600 Spec E 800 1000 Ampere switches Removing Switch Assembly Normal or Emergency 1 Remove the linear actuator as described in Linear Actuator Removal and Replacement section for 600 Spec E 800 1000 Ampere switches Follow step 1 through 7 in the Removing Actuator section 2 Remove the red plastic contact covers by spread ing them slightly at the bottom until they can be lifted off the contact assemblies 3 Lift the arc chute covers off the arc chutes 4 Remove the hex head capscrews locking washers and flat washers that secure the inter lock bar to the interlock arm Figures 33 and 34 and remove the interlock bar 5 Disconnect the control wiring leads from the jumper bus bars 6 Remove the hex head capscrews ring terminals flat washers spring washers and nuts that secure the jumper

(spec E-F) Transfer Switch Service manual (12

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