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1. 12 12 12 Installed Not Wired Emergency Connected Relay Normal Connected Relay Emergency Source Available Relay Normal Source Available Relay Installed Not Wired Emergency Relay Normal Relay Genset Run Rel y Installed Not Wired Emefgency Relay NormalRelay Genset Relay 5 12 Alarm Module Option The optional alarm module Figure 5 13 provides an audible indication that the transfer switch has transferred to the source 2 power source A push button on the alarm module provides a means to sllence the horn The Alarm lamp indicates that the transfer switch is in the Source 2 Connected position If the hom is silenced the Hom Silenced lamp will also light Both lamps will stay lit until the transfer switch moves from the Source 2 Connected position to the disconnected neutral or Source 1 Connected po sition Standby Set Start Sequencer Option The optional standby set start sequencer Figure 5 14 is available and applicable only on genera tor set to generator set transfer switches In dual standby applications the power cables from two generator sets are connected to source 1 and source 2 lugs of a generator set to generator set transfer switch which in turn provides power tothe generator set source lugs on a utilitysto gen rator set transfer switch The function of the standby set start sequencer is to respond to a remote start sigrial f
2. 2 2 2 17 Adjusting Power Sentry Mod les 2 2 22 Adjusting Optional Control Modules and Accessories 2 24 3 TROUBLESHOOTING 3 1 Transfer Switch Does Not Retransfer 3 2 Source 1 Voltage Sensor Does Not Sense Voltage 3 4 Transfer Switch Does Not 3 5 Source 2 Voltage Sensor Does Not Sense Voltage 3 7 Generator Set Does Not Crank Two Wire Start 3 8 Generator Set Does Not Crank Three Wire Start 3 9 4 TRANSFER SWITCH ASSEMBLY 4 1 Kw uc 4 1 POWOE 2 RR 4 1 Reconnecting AC Power When Finished 4 1 Linear Actuator Removal and Replacement 40 to 125 Amperes 4 1 Block and Crossbar Removal and Replacement 40 to 125 Amperes 4 4 A xiliary Switch Removal and Replacement 40 to 125 Amperes 4 7 Linear Actuator Removal and Replacement 150 to 260 Amperes 4 9 Block and Crossbar Removal and Replacement 150 to 260 Amperes 4 12 Auxiliary Switch Removal and Replacement 150 to 260 Amperes 4 15 Linear Actuator R
3. 7 1 Introduction uu u l as L KU ee ba ae 7 1 Cabinet dn alo 7 2 Transfer Switch L m 7 3 Optional Control Components 2 225 7 5 s coss ee Bade aa 7 7 Troubleshooting 7 8 SCHEMATICS AND WIRING DIAGRAMS 8 1 Mother Board 300 3953 Utility to Generator Set 8 3 Mother Board 300 3267 Utility to Utiliy 8 4 Mother Board 30043090 Utility to Generator Set 8 5 626 1762 Sheet or 8 6 626 1762 ZW 5 8 7 626 1762 3 f 5 8 8 626 1762 4 of B 8 9 626 179 Je DO0t B of 5 dieses cer one wed dna RO Oo P En 8 10 Open Wiring Diagrams 8 11 AWARNING INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH SEVERE PERSONAL INJURY AND OR EQUIPMENT DAMAGE SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND OR MECHANICAL SERVICE Safety Precautions This manual includes the following symbols to indi cate potential
4. 2 7 amp 8 307 2801c 52 L Je DDO L dL KJ Esse F 4 3 11110 N39 111n F d i g m g 2 13 Float Battery Charger The optional float charge battery charger Figure 2 10 regulates its charge voltage to continuously charge the battery As the battery approaches full charge the charging current automatically tapers to zero amperes or to steady state load on the bat tery There are two chargers available One battery charger is rated for 10 amperes at 12 or 24 VDC The other battery charger is rated for 2 amperes at 12 or 24 VDC Power to the battery charger is supplied directly from the Normal source through connector J1 P1 on the Accessory Control Panel The output of the battery charger is connected to the GND and terminals of TB2 or TB3 if the 3 Wire Start module is used Referto the drawing referenced on sheet 3 of your schematic and wiring diagram package The 2 ampere battery charger has an ammeter to indicate charging current and a fuse to protect the battery charger circuit The 10 ampere battery charger has three fuses two on the AC input and one on the DC output three fault display LEDs and an ammeter for indi cation of charging current On the 10 ampere charger three sets of form C alarm contacts corresponding to the three fault LEDs are also available These contacts can be wired by the i
5. over crank relay a preheat relay two 4 Lockout Lamp a Reset Switch Auto Stop Handcrank Switch Figure 5 6 The 3 Wire Start module may be equipped with a preheat timer On Off switch Overcrank occurs when the generator set does not start within the adjustable time limit Jn order to pro tect the starter motor relay contacts open the starting circuit and light the Lockout lamp After a starting problem 15 pressing the Overcrank Reset switch resets the circuit Refer to the Operation Section A set of overcrank alarm contacts are also pro vided The contacts canbeusedto energize an ex ternal overcrank alarm The 3 Wire Start module has two adjustable timers The timer delays the start signal to allow preheating the generator set The Preheat timer s range of adjustment is 0 to 60 seconds If the module has a Preheat On Off switch make sure that it is in the correct position GND 1 2 UNIT 1 B 3 RMT 4 RMT 5 UNIT 2 B 6 7 8 1575 78 FIGURE 5 5 TWO WIRE START CONNECTIONS e 3 Wire Start e Auto Handcrank Stop 10 Timing E on Delay Seconds 60 Timing Delay Seconds 0 120 Lockout 6 Preheat Overcrank Overcrank Reaet FIGURE 5 6 THREE WIRE START MODULE The Overcrank timer limits the time that the genera tor set starter is allowed to operate
6. 60 Program Transition e FIGURE 7 6 PROGRAM TRANSITION MODULE Alara Module OPERATION Local Operation Transfer switch operation results in rapid movement of the manual operator han dles and presents a hazard of severe personal Injury Keep the cabinet door closed To set the transfer switch for local operation 1 Place the Local Remote switch in the Local position 2 Place the Motor Disconnect switch on the Ac cessory Control Panel in the Auto position To transfer the load to the Standby source 1 Check that the Standby Available lamp is lit The transfer switch will only permit transfer to the Standby source if the Standby source volt age is available 2 Move the Normal Standby switch to the Standby position and hold it there until the Standby Connected lamp is lit To transfer the load to the Normal source 1 Check that the Normal Available lamp is lit The transfer switch will only permit transfer to the Normal source if the Normal source age is available 2 Move the Normal Standby switch to the NOr mal position and hold it there until the Normal Connected lamp is lit Remote Operation Transfer switch operation results in movement of the manual operator han dles and presents a hazard of severe personal Injury Keep the cabinet door closed during re mote operation To the transfer switch forremote operation 1 Place the Local Remote switch in the Remote posit
7. Connect the control wiring leads to the corre sponding power source terminals Control wires are marked NORM A B C N or EMER A B C N for identification the current carrying surfaces of the jumper bus bars and load bus bars with a wire brush Install the A B and C jumper bus bar load bus bar load lug support block assembly Secure to the block and cross bar assemblies with hex 4 15 10 11 12 13 14 15 16 head capscrews and spring washers Tighten to 1010 12 ft lbs 13 6 to 16 3 Nem torque Se cure the load lug support block with screws Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem torque Connect the control wiring leads to the corre sponding jumper bus bar terminals Control wires are marked LOAD A B C N for identifica tion Place the handle assembly in position on the block and cross barassembly and secure with the two machine screws and mounting plate Tighten to 15 to 20 in Ibs 1 7 to 2 3 Nem torque Apply asthin coat of lubricant Onan part number 524 0157 to the slot in the han dle Apply thread sealant blue Loctite 242 Onan partnumber 518 0309 is recommended tothe threads of the interlock bar capscrews Install the interlock bar and secure to each interlock arm with a hex head capscrew lock washer and flat washer Tighten to 70 to 75in lbs 7 9 to 8 5 Nem torque Attempt to close both sides of the transfer switch The interlock assembly mu
8. Replace the time delay board Turn the transfer delay potentiometer on the time delay board to mini mum fully counterclockwise Ifthe Transfer Timing Complete lamp does not come on withimtwo minutes then replace the time delay board If the Transfer Timing Complete lamp does come on but the transfer switch still doesn t transferthen go to Step 7 7 Is the Mot r Disconnect switch on the accessory control panel in the Auto position 8 Place the Motor Disconnect switch in the Auto position Does the transfer switch transfer 9 the optional Signal Module is used check that the ribbon cable from the mother board to the option board is connected properly If the cable is OK then place the Delay No Delay switch on the option board in the No De lay position Does the switch transfer 10 Replace the Signal Module nn o N 3 5 AC power within the cabinet and rear side of the cabinet door presents shock hazard that can cause severe personal Injury or death The following procedures are to be performed only technically qualified personnel Use extreme caution to avold touching electrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components TROUBLESHOOTING 3 3 Continued Transfer Switch Does Not Transfer During a Power Failure Test or Exercise This procedure is to be performed
9. The most important component of the electronic control system is the Power Sentry Control The Power Sentry includes voltage sensing circuits time delay circuits and control relays There are also several adjustment potentiometers and indica tor lamps on the Power Sentry The adjustments must be performed only by qualified service per sonnel Power Sentry Time Delays Start Time Delay This delay is adjustable from Oto 15 or optionally O to 90 seconds This brief time delay prevents generator set starting during power interruptions of short duration Timing starts the moment of Normal utility power interruption If the duration of the interruption exceeds the delay time the control system signals the generator set to start Stop Time Delay This delay is adjustable from Oto 10 minutes It begins timing when the load is retransferred to the Normal power source At the end of the delay the stop signal is sent to the gen erator set This time delay allows the generator set to cool down at no load before stopping Transfer Time Delay This delay begins when generator voltage and frequency reach the settings of the control After the delay the transfer switch transfers the load to the Emergency power source This brief time delay allows the generator setto sta bilize before the load is applied It has an adjust able range of to 120 seconds Retransfer Time Delay This delay begins the mo ment Normal line voltage and fr
10. 3 9 AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when th cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the control panel before removing and replacing components TROUBLESHOOTING 3 6 Continued Generator Set Does not Crank for a Power Failure Test or Exercise Using a Switching Ground Three Wire Starting System This procedure is to be performed with the line voltage available and the Test Normai Retransfer switch In the Test position 14 Press and release the Overcrank Reset button Does the 15 21 light 15 After the preheat time delay does the Overcrank Timing lamp fight 16 23 16 Does the generator set crank 17 18 17 If the generator set cranks but does not start there generator set X X problem 18 Is there 0 VDC at TB3 4 19 20 19 There is a generator set problem X X 20 There is an open between TB3 4 and J11 8 or the 3 WireStart module is X X bad 21 Isthere9to 12 VDC between the anode 2 on the mother board and 22 24 ground 22 There is a bad connection in the between the mother board X X and the 3 Wire Start module 23 The 3 Wire Start module is bad afid mus
11. AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death Disconnect connector J1 P1 before working on the electronic control system Disconnecting J1 P1 removes all power to the door except for customer Introduced power at the Signal Module Be sure to remove all power before replacing components No special tools are required to remove and re place control system components The mother board and transformer assembly are held in place by several screws and will not fall when the four screws that secure the Power Sentry cover are removed Be sure to use all of the hard ware when remounting components 1 10 TABLE 1 2 LUG TIGHTENING REQUIREMENTS SET SCREW SOCKET SIZE ACROSS FLATS 3 16 IN 1 4 IN 5 16 IN 3 8 IN 1 21 9 16 IN MINIMUM TORQUE FOR PROPER OPERATION 80 IN LBS 9 Nem 200 IN LBS 23 Nem 275N LBS 31 Nem 375 IN LBS 43 Nem 500 IN LBS 57 Nem 600 IN LBS 68 Nem FEATURE FEATURE DESCRIPTION OPTION Poles SPOS s RE A028 4 t E NIU RS A029 Application Appl Utility to Genset A035 Appl Utility to Utility A036 Appl Genset to Genset A037 Appl Nonautomatic A038 Agency Approvals Listing UL A046 Certification CSA A047 Listing Not Applicable A048 Frequency 60 Hert
12. PREFERRED SOURCE SELECTOR SWITCH 12 SHOWN IN THE SOURCE 1 POSITION OPTIONAL AUTO MANUAL SWITCH PERFERRED SOURCE SELECTOR SWITCH X CLOSED MOMENTARY CONTACT AUTO MANUAL SELECTOR SWITCH SPRING RETURN TO CENTER GENERATOR SET TO GENERATOR SET CUSTOMER CONNECTIONS MOUNTED LEFT SIDE OF CONTROL PLATE CUSTOMER MUST MOUNT ANO WIRE LAMPS SWITCHES SHIPPED LOOSE SOURCE A POSITION SOURCE 2 POSITION SOURCE 1 AVAILABLE SOURCE 2 AVAILABLE bd moscoo SOURCE 1 AUTO SOURCE 2 SWITCH a iei qu ne e cies ax 612 574 8087 an is a registered trademark of Onan Corporation
13. assemblies to the end of the actuator rod Remove the rod end assembly Figure 4 16 and slide the actuator rod out of the actuator motor Loosen and remove the twelve machine screws with flat washers that three plastic switch covers to the switch base and lift off the switch covers Fig re 4 16 Remove the hexhead machine screws that se cure the terminal bracket t the base Move the bracket to the side to allow jaccess to the auxiliary switch terminals Remove the control wiringleads from the auxil iary switch terminals Figure 4 20 Close the transf r switch to the side you are working on and rem ve the hex head machine screws that secure the auxiliary switch assem bly brackets tothe base Lift out the auxiliary switch assembly Remove the round head machine screws Flat washers and nuts that secure the auxiliary Switches to the bracket Figure 4 20 and lift out the auxiliary switches and insulating barri ers 4 32 Replacing Auxiliary Switch Assembly 1 Install the insulating barriers and auxiliary switches in the brackets and secure with head capscrews 2 and nuts 2 Note that each switch must be assembled so thesside with two terminals faces inward Figure 4 20 when the auxiliary switch assembly isinstalled Install the auxiliary switch assembly on the base and secure the bracketto the base using the hex head machine serews Tighten to 25 to 30 in
14. This functions to prevent generator shut off until retransfer to the Normal side occurs There are two run Interlock relay onsthe generator set to generator set mother board Additional outputs from the mother board include e Start Genset outputs e Source 1 and 2 Available outputs e Transfer and R transfer outputs e Backup Source Failure outputs Start Genset and Source 2 Available outputs are available f r connection to the optional 3 Wire Start module The generator set to generator set mother board includes a Start Genset 1 output and a Start Genset 2 output These two outputs as well as Source 1 Source 2 Available outputs are available for connection to the two optional 3 Wire Start mod ules Start Genset Source 1 Available Source 2 Avail able Transfer Retransfer and Backup Source Failure outputs are available for connection to the optional Signal Module relay board Voltage Sensor Modules The voltage sensors are plug in modules that fit into the J1 and J3 edge connectors on the mother board The voltage sensors monitor the voltage sources single or three phase and provide an out put signal Source Available when the source is within predetermined limits Depending on the op tions selected the sensors test for undervoltage overvoltage and under overfrequency The Source Available output signal is latched on when all of the pickup requirements for voltage and frequency are satisfied The Sour
15. e o amp o 3 2 u M N 2 LBS 2 8 TO TORQUE 25 30 IN SC1570s FIGURE 4 16 TRANSFER SWITCH COVER 800 1000 AMPERES 4 26 Insertthe actuator rod into the replacement ac tuator motor Figure 4 17 Hold the actuator ground brush up slightly to allow passage of the actuator rod Secure the rod end assembly to the actuator rod with the hex head capscrew flat washer and lock washer Tighten the capscrew to 70 to 75 in Ibs 7 9 to 8 5 Nem torque Fit the rod assembly into the handle of the closed switch assembly 9 10 11 Check the operation of the transfer switch and the alignment of the actuator rod opening and closing both the Normal Emergency switch assemblies If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emer gency power source Place the operation se lector switch in the Remote position Test the switch for proper operation and close the cabinet FIGURE 4 17 LINEAR ACTUATOR 800 1000 AMPERES 4 27 BLOCK AND CROSS BAR ASSEMBLY REMOVAL AND REPLACEMENT 800 and 1000 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control p
16. REFER TO THE 5 SHEET SCHEMATIC AND WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR TRANSFER SWITCH REAR WALL OF CABINET TRRNSFER SWITCH de ES i m N lt m o ot 54 NC NO 1 1 N 1 1 l 1 A eds NON LEA an an i M1 8 K 2 6 LB C1 1 RED CB1 1 C1 2 3 P1 9 N 59 NO E M1 WHT U SOME UNITS USE TWO CRPRCITORS T SEE 626 1690 0 FOR TE WIRING R R Em P1 12 STANDARD WIRING 626 1762 sh 4 of 5 MODIFIED UTILITY TO GENERATOR SET CUSTOMER CONNECTIONS MOUNTED ON LEFT SIDE OF CONTROL PLATE CUSTOMER MUST MOUNT AND WIRE LAMPS SWITCHES SHIPPED LOOSE NORMAL POSITION EMERGENCY POSITION NORMAL AVAILABLE OPTIONAL AUTO MANUAL SWITCH AUTO MANUAL SWITCH NONAUTOMATIC CUSTOMER CONNECTIONS MOUNTED ON LEFT SIDE OF CONTROL PLATE E CUSTOMER MUST MOUNT AND WIRE LAMPS SWITCHES SHIPPED LOOSE NORMAL POSITION STANDBY POSITION NORMAL AVAILABLE D STANDBY AVAILABLE X CLOSE 542 NORMAL STANDBY SWITCH S14 LOCAL REMOTE SWITCH S14 SHOWN THE REMOTE POSITION OPEN CONSTRUCTION WIRING DIAGRAMS 8 11 UTILITY TO UTILITY CUSTOMER CONNECTIONS MOUNTED ON LEFT SIDE OF CONTROL PLATE CUSTOMER MUST MOUNT AND WIRE LAMPS SWITCHES SHIPPED LOOSE SDURCE 1 POSITION SOURCE 2 POSITION SOURCE 1 AVAILABLE SOURCE 2 AVAILABLE X CLOSED
17. REMOVAL AND REPLACEMENT 40 to 125 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal Injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the auxiliary switch for 40 to 125 ampere switches Removing Auxiliary Switch Assembly 1 Open the transfer switch cabinet door 2 Loosen and remove the four machine screws with flat washers that secure plastic switch cover to the switch base and liftoff the cover 3 Loosen the two machine screws thatsSecure the terminal bracket to the Move the ter minal bracket to allow the auxiliary Switches 4 Remove the control wiritig leads from the auxil iary switch terminals Figure 4 5 5 Remove the hex head machine screws that se cure the auxiliary switch assembly bracket to the base 6 Disengage auxiliary switch lever from the transfer Switch crossbar and lift out the auxil iary switch assembly Use
18. Remove the two threaded hex spacers from the back of each block assembly and save for reuse On 4 pole switches Flgure 4 9 With a screwdriver dig the glue out of the cavity in the base of the neutral block Remove the ma chine screw that secures the neutral block and remove the neutral block Remove the two round head machine screws that secure the interlock arm to the block and cross bar assemblies and lift off the interlock arm Remove the hex head capscrews ring termi nals spring washers and lug terminals from the block and cross bar assembly JUMPER BUS BARS 15 NORMAL JEA IO Lf G TORQUE 25 30 INABS 2 8 3 4 Nem TORQUE TONO TOAZ FT LBS 18 6 TO 16 3 Nem 15 TO 20 IN LBS 1 7 TO 2 3 Nem 7 TO 75 IN LBS 7 9 TO 8 5 Nem FIGURE 4 8 3 POLE SWITCH ASSEMBLY 150 TO 260 AMPERES 4 13 JUMPER LOAD BUS BUS BARS BARS E 2e ium om O x 2 s 19 NH g bale wu esp d INTERLOCK ARM 1 TORQUE 25 TO 30 N LBS 2 8 3 4 2 TORQUE 10 TO 12FT UBS 13 6 16 3 Nem TORQUE 20 IN LBS 1 7 TO 2 3 Nem 2 TORQUE 70 75 IN LBS 7 9 TO 8 5 Nem FIGURE 4 9 4 POLE SWITCH ASSEMBLY 150 TO 260 AMPERES 4 14 Replacing Block and Cross Bar Assembly 1 I
19. The following procedures cover the removal and replacement of the linear actuator for 800 and 1000 ampere switches Removing Actuator 1 2 Open the transfer switch cabinet door Remove a hex head capscrew flat washer and lock washer that secures one of the rod end assemblies to the end of the Remove the rod end assembly Figure 4 16 and slide the actuator out actuator motor Loosen and remove twelve machine screws with flat washers that secure the three plastic switch coverstto the switch base and lift off the switch Covers Figure 4 16 Separate the actuator lead wires from the rest of the wiring harness remove the wire ties as required Pry the Capacitors loose from the brackets Remove and disconnect the red and white actuator lead wires from the capaci tor terminals 4 25 7 Disconnect the black actuator lead wire from the circuit breaker and the ground wire from the end of the actuator 8 Remove the hex head capscrews flat wash ers and lock washers that secure the actuator to the switch assemblies Figure 4 16 and lift out the spacers and actuator motor Replacing Actuator 1 Hold the actuator motor and spacers 4 in po sition over the switch assemblies with the lead wires at the bottom Secure the actuator motor to the switch as semblies usihg hex head capscrews 4 lock washers 4 pand flat washers 4 Tighten
20. and spacers 1 12 Remove the allen head capscrews and lug ter minals from the block assemblies 13 Remove the hex head capscrews and flat washers that secure the cross bar assembly to the base and lift off the cross bar assembly Use care when removing the block and cross bar assembly from the base Carefully disengage the crossbar from the auxiliary switch assembly to avoid cracking the switch 14 Remove the shoulder screws and self locking nuts that secure the two halves of the handle assembly together Remove the shoulder screws and lock washers that secure the han dle assembly to the block and cross bar as sembly Slide the two halves of the handle apart and remove them 15 Remove the two round head machine screws that secure the interlock arm to the cross bar assembly and lift of the interlock arm INTERLOCK CROSSBAR ARM 3 ASSEMBLY i TN IQ Tm W wv lt JUMPER BUS BAR 1 TORQUE 15 TO 20 IN LBS 1 7 TO 2 3 Nem Z TORQUE 25 TO 30 IN LBS 2 8 TO 3 4 Nem 8 TORQUE TO 70 TO 75 IN LBS 7 9 TO 8 5 Nem A TORQUE TO 28 TO 33 FT LBS 40 0 TO 44 7 Nem S TORQUE 18 TO 20 FT LBS 24 4 TO 27 1 Nem 6 TORQUE 10 TO 12 FT LBS 13 6 TO 163 Nem SC1567s FIGURE 4 18 3 POLE SWITCH ASSEMBLY 800 1000 AMPERES 4 29 INTERLOCK CROSSBAR ASSEMBLY IN
21. eration results rapid movement of the manual operator handles and presents a hazard of severe personal Injury Keep hands clear of handles when switching back to automatic operation Move the Motor Disconnect switch to the Auto position 6 Close and lock the cabinet doof TROUBLESHOOTING The following procedures describe preliminary troubleshooting checks AC power withinthe cabinet and the rear side of th cabinet door presents a shock hazard that severe personal Injury or death For this reason do not touch or allow clothing tools or jewelry to contact exposed electrical terminals whenever the cabinet door 5 open sure you are standing on a dry Insulating surface 5 Transfer Switch Does Not Transfer Automatically 1 Check the Motor Disconnect switch It should be in the Auto position Is the Source Selector switch in the correct po sition Has the transfer time delay expired Has the programmed transition time delay if equipped expired Is backup source voltage sufficient to trigger the backup source voltage sensor 2 3 4 5 Transfer Switch Does Not Retransfer Automatically 1 Check the Motor Disconnect switch It should be in the Auto position Is the Source Selector switch in the correct po sition Has the retransfer time delay expired Has the programmed transition time delay if equipped expired Is preferred source voltage sufficient to trigger the p
22. fromO to 120 seconds The Source 1 Available and Retransfer Complete lamps remain on during the timing period If the voltage returns to normal dur ing the timing period the sensor resets itself The optional over underfrequency sensor begins timing if the source frequency rises above or falls below the dropouttsetting The frequency dropout time delay is adjustable from to 15 seconds Un less power 505 completely both the Source 1 Available lamp and the Retransfer Complete lamp remain on during the timing period If the frequency feturns to normal during the timing period the sen sor resets itself Start Time Delay If the Normal power source is still faulty after the voltage sensor has timed out all indicator lamps go out and the start time delay be gins timing The starttime delay is adjustable from to 15 seconds or optionally from O to 90 sec onds All lamps stay out while the start time delay is timing The start time delay prevents generator set startup when a power interruption of very short duration occurs If the Normal power source re turns during the timing period the start time delay is reset Capacitor C1 on the mother board provides power to the time delay module during this timing period Because the generator set start signalis in itiated by de energizing a relay a complete dis charge of C1 produces a start signal After the start time delay has timed out a signal from the time delay module de
23. gized its contacts direct Normal power to the linear actuator retransferring the load backto the Normal power source Without programmed transition the finear ac tuator circuit path includes K1 contacts Circuit breaker CB1 Motor Disconnect switch 51 and auxiliary switch S4 Capacitor s C1 provides the phase shift necessary to drive the linearjactuator If the Program Transition modules used there is a pause 0 to 60 or 0 to 7 5 seconds at the neutral position The timing of this pause is controlled by the Program Transition module The linear actua tor drive circuit is and auxiliary switch S9 With programmed transition the circuit path pro vided by theMormally closed contacts of and auxiliary switch S9 allows the switch to move from the Emergency side to the neutral position Switch S9 then breaks the linear actuator drive circuit forcing the switch to wait for the Program Transition modul to time out Afterthe normally open con Program Transition module close the circuit path to the linear actuator is completed and the switch is transferred to the Normal side The Retransfer Complete lamp lights and stays lit as long as the control is signaling for the load to be connected to the Normal power source 2 19 Auxiliary switches S2 S3 S4 and S5 arg actuated when the transfer switch is in the Normal position Switch S4 acts as a limit switch to br a
24. handles when switching back to automatic operatlon 3 3 Troubleshooting Electronic Control System This section covers troubleshooting procedures for the utility to generator set automatic transfer switch Although some of the information is applicable to generator set to generator set utility to utility and nonautomatic remote configurations there are several significant differences Refer to section 5 for an overview of generator set to generator set transfer switch troubleshooting Refer to section 6 for an overview of utility to utility transfer switch troubleshooting Refer to section 7 for an overview of nonautomatic remote transfer switch troubleshooting Refer to the five sheet schematic and wiring dia gram package that was shipped with the transfer switch for specific information about its configura tion AWARNING AC power within the cabinetand the rear side of the cabinet door presents 5 hazard that can cause severe personal Injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door Is open Remove power to the door by discon necting connector J1 P1 the accessory control panel before removing and replacing components The following procedures are to be performed only by technically qualified personnel TROUBLE Transfer Switch Does Not Retransfer Source 1 Voltage Sensor Does Not Sense Voltage Transfer Switch Does No
25. tact assemblies linear actuator Motor Disconnect Switch and auxiliary contacts Contact Assemblies The automatic transfer switch has either three four poles Three pole switches are pro vided with a neutral The contact assemblies make and break the c rrent flow When closed to either the source Tor the source 2 generator set the contacts ar mechanically held A mechanical interlock prevents them from closing to both gen erator sets at the same time Linear Actuator The linear actuator is a linear induction motor that movesSthe contact assemblies between the Normal source 1 side and the Emergency source 2 side Linear actuator operation is initiated automatically with automatic transfer switches Manual operation of the transfer switch is also possible Refer to Manual Operation in the Operation section 5 3 Motor Disconnect Switch The Motor Disconnect toggle switch on the acces sory control panel enables and disables the linear actuator Place the switch in the Auto position to enable the linear actuator Place the switch in the Off position to disable the linear actuator Auxiliary Contacts Auxiliary contacts are provided on the Normal source 1 and Emergency source 2 sides of the transfer switch They are actuated by operation of the transfer switchduring transfer and retransfer The Normal side auxiliary contact switch is actu ated when the transfer switch is in the Nor
26. the switch is transferred to the Emergency Side The Transfer Complete lamp lights and stays on as long as the control is signaling for the load to be connected to the Emergency power source Auxiliary switches S6 S7 58 and 9 are actuated when the transfer switch isin the Emergency posi tion Switch S8 acts asa limit switch to break the circuit path to the linearactuator Switch S7 breaks the circuit path to the coil of relay K2 and lights the Emergency on the door Emergency Power Source Connected to Load The Sourceg2 Available lamp is on to indicate that the Emergency power source is within the voltage and frequency settings of the voltage sensor Transfer Complete lamp is on to indicate that the eontrolis signaling for the load to be connected to Emergency power source The Start Gen Set lamp 15 to indicate that the control is signaling for the generator set to run When the transfer switch is in the Emergency posi tion and the Emergency source is energized K16 is energized by the action of position sensing auxil iary switch 57 When K16 is energized its run inter lock contacts K16 2 K16 4 are open preventing K11 from being re energized This prevents the control from stopping the generator set as long as it is still powering the load Normal Power Source Returns The time delay module is programmed to identify the Normal power source as the preferred power source The return
27. the transfer signal is delayed for a preset time 0 50 seconds During this delay the Signal Module energizes an Elevator Signal relay to announce that a transfer is about to occur When K14 is energized with or without the Signal Module delay its normally open contacts close and energize transfer relay K2 When K2 is ener gized its contacts direct Emergency power to the linear actuator transferring the load todhe Emer gency source Without programmed transition sthe linear ac tuator circuit includes K2 Contacts circuit breaker CB1 Motor Disconnect switeh S1 and auxiliary switch S8 Capacitof s the phase shift necessary to drive the linear actuator If the Program Transition module Is used there is a pause 0 to 60 or Oto 7 5 seconds at the neutral position The timing of this pause is controlled by the Program Trafisitign module The linear actua tor drive circuit is controlled by K2 and auxiliary switch S5 With programmed transition the circuit path pro vided by the normally closed contacts of K3 and auxiliary switch S5 allows the switch to move from the Normal sige to the neutral position Switch S5 then linear actuator drive circuit forc 2 18 ing the switch to wait for the Program Transition module to time out Afterthe normally open K3 con tacts on the Program Transition circuit path to the linear actuator is completed and
28. with a ball point pen to clear the program 3 Press the Pr button 8 to return to the time of day display Two Wire Starting The starting circuit is a basic supervisory function of the electronic control Although the logic is more involved the two wire starting circuit can be thought of as a single pole single throw switch A closed switch signals the generator set to start An open switch signals the electric generator set to stop The two wire start circuit uses terminals GND ground and RMT of terminal block TB2 Figure 5 5 There are two and two RMT terminals on TB2 The upper and terminals are con nected to like terminals on unit 2 The lower B and RMT terminals are connected to like terminals on unit 1 The TB2 GND terminal is connected to the GND terminals on both units In some applications the jumpers between terminals 2 and upper and between 7 and lower are removed Refer to the generator set control schematic and to the in terconnection wiring diagram Three Wire Starting Option The optional three wire starting control available on 40 to 125 ampere switches only enables the transfer switch to start and stop a three wire start generator set Three wire starting logic is similarto a single pole double throw switch A common is closed to one side to send a start signal and to the opposite side to send a stop signal In addition to start and stop functions the control has
29. 1 70 AVAILABLE SIGNAL MOD 2023 B EQ SIGNAL 4 2023 gt 11 Arv 9 WIRE 1 i 1 1 n crs GND 1 i I I 1 un 1 RB 1 5 3 H K20 2 s I gt x 3k19 2 M I TAMEN SA PARTS NOT ADDED ON THIS ASSY INDICATOR D USED ONLY ON AREA PROTECTION ABBY i i I 1 INDICATOR 1 dun ADI ERR 4 SCHEMATIC OF MOTHERBOARD 300 3953 UTILITY TO GENERATOR SET 8 3 START GENSET K11 2 GND OR 4 no connection CR 8 14 2 3 MIRE COM 300 3953 MODIFIED TRANSFER CONTACT 4 22 RETRANSFER bkis CONTACT J7 ex TEST EXERCISE 0 LOAD SW SI 20 30VDC 12 0 5vDC CRS 2 1 mc 2 1N4004 3 144004 4 i6 Le qug CRIS CRI7 SWITCH 144004 114004 52 CRI8 CRIS Q 2 184004 144004 z Je 52 9 gt 4 CR20 144204 194004 CR24 25 J6 a gt SIGNAL g MODULE J7 TEST SWITCH EXERCISE CLOCK S s L CR22 CR23 9 6 rc 184004 1 4004 Q ii S CR26 CR27 27127 ee i R 9 6 INSTANT i n hear REXFR I 4 FS m m 2 cos E com 7 7 3 4 p 7 SIGNAL 2003 AVAIL SCHEMATIC OF MOTHER BOARD 300 3090 UTILITY TO GENERATOR SET 8 5 SOURCE
30. 2 6 SIGNAL MODULE Exerciser Clock The optional exerciser clock Figure 2 7 initiates generator set start run cycles at programmable in tervals and for programmable durations It is a 7 day 24 hour clock that can store and execute up to ten start stop programs exercise cycles Instead of an exerciser clock generator set to gen erator set transfer switches may Include an optional change over clock Refer to section 5 If applicable Programming the exerciser clock requires setting the time of day and entering the exercise start and stop times This procedure is described under Ad justing Optional Control Modules The output of the exerciser clock is a set of normally open contacts that when closed provide a ground to the Power Sentry mother board schematic in section 8 input J7 8 This signal energizes test ex ercise relay K13 on the mother board The Exercise With Without Load switch provides the option of transferring or nottransferring the load during the exercise periods The three position switch in the lower left corner of the clock can be used to override the programi o test the exercise function close the output con tacts place the switch the position 9155 able the exercise function hold the output contacts in the open position place the switch position For normaloperation output contacts un der program control place the switch in the center clock position
31. As with the standard undervoltage sensing the voltage sensors signal the time delay module which controls the transfer or retransfer sequence An adjustable time delay overrides momentary overshoots in voltage Frequency Sensing With optional frequency sensing the Normal and Emergency sources are monitored for variations in frequency The sensors detect whether or not the source is within an adjust able bandwidth As with the standard undervoltage sensing the fre quency sensors signal the time delay module which controls the transfer or retranSfer sequence An adjustable time delay allows the control to ig nore momentary dips or rises if frequency Two Wire Starting The starting circuit is a basic Supervisory function of the electronic control Water cooled generator sets use a two wire start control Although the logic 15 involved the two wire starting circuit can be thought of as a single pole single throw switch A closed switch signals the generator s t to start An open switch signals the electric generator set to stop Three Wire Starting Option The optional three wire starting control available only on 40 to 125 ampere units enables the trans 1 6 fer switch to start and stop a three wire start gen erator set Three wire starting logic is similar toa single pole double throw switch common is closed to one side to send a start signal and to the opposite side to send a stop signal I
32. CROSSBAR ASSEMBLY BLOCK AND CROSSBAR ASSEMBLY 5 1564 Replacing the Block Cross bar Assembly Normal or Emergency 1 Install the interlock arm on the block assembly using the capscrew and lock washer Figures 4 13 and 4 14 Torqueto 70 to 75 in Ibs 7 9 to 8 5 Nem On 4 pole switches Figure 4 13 Secure the block and contact assembly to the base us ing the four screws removed in step 10 above Tighten the screws to 25 to 30 in Ibs 2 8 to 3 4 Nem Placethe bearing bracket removed in step 9 in position on the end of the cross bar assembly Install the block and cross bar assembly on the transfer switch base with the screws lock washers and flat washers carefully engaging the auxiliary switches Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem On 4 pole switches tighten the bearing bracket screw to 25 to 30 2 8 to 3 4 Nem Clean the current carrying surfaces of the block assembly and the lug terminals with a wire brush Install the lug terminals with the round head screws and lock washers Tighten to 70 to 75 in lbs 7 9 to 8 5 Nem Secure the jumper bus bars to the 5 sembly with the capscrews and spring wash ers Make sure the mating surfaces coating of electrical joint compound Tighten the capscrews 10 to 12 ft lbs 13 6 to 16 3 Nem Secure the load bus bars to the bus bars with the capscrews lock washers flat wash
33. Momentary voltage dips can cause voltage sensors to initiate generator set starting Generator Set Does Not Start When A Change over Is Scheduled 1 Two wire starting only The operation selec tor switch on the generator set control panel should be in the Remote position AC power within the cabinet and the rear side of the cabinet door pre sents a shock hazard that can cause severe personal Injury or death For this reason do not touch orallow clothing tools or jew elry to contact exposed electrical terminals whenever the cabinet door 15 open Make sure you are standing on a dry Insulating surface Three wire starting only The Auto Stop Handcrank switch on the 3 Wire Start module should be in the Auto position Check the change over clock to verify the change over schedule The procedure for checking the change over program is de scribed under Programming the Change over Clock If a change over 15 incorrectly programmed re fer to the change over clock programming pro cedure 4 Start the generator set using its start stop con trols The Auto Stop Handcrank switch on the 3 Wire Start module must be in the Handcrank position If it does not crank check the start ing battery it cranks but does not start check the fuel supply Ignition of explosive battery gases can cause severe personal Injury Do not smoke or cause any spark or flame while servicing batteries Ignition of fuel can cause
34. Overvoltage Cal potentiometer fully Clockwise The Source Available lamp for the selected source should light Turn the Overvoltage Cal potentiometer coun terclockwise until the Source Available lamp turns off Slowly turn the Overvoltage Cal potentiometer clockwise until the Source Available lamp just turns on again Overvoltage Dropout and Time Delay Adjustments The overvoltage sensor has an adjustable dropout and time delay Dropout occurs when an overvolt age condition is sensed The dropout time delay al lows the control to ignore momentary voltage over shoots Pickup is fixed at five percent below the dropout setting Overvoltage dropout and time de lay are adjustable over the following ranges Function Adjustment Range Dropout 105 to 135 of nominal voltage Delay 0 to 120 seconds To set the dropout percentage and time delay align the slots on the potentiometers with the desired markings on the Power Sentry cover Figure 2 14 Frequency Sensor Adjustments The optional frequency sensor monitors the source frequency When the source frequency is outside the acceptable band dropout occurs The bandis centered about the nominal system frequency 50 or 60 hertz The dropout bandwidth is 2 5 wider on each end than the pickup bandwidth The pickup bandwidth is adjustable An adjustable dropout time delay allows the control to ignore momentary dips or rises in frequency Frequency sensor pickup bandwidth
35. accomplished by sensing the source frequency and detecting when it is within a specific band The pickup bandwidth is adjusted with a potentiometer refer to Adjusting Power Sentry Modules in this section The pickup adjustment range is 5 to 20 of the nominal fre quency The dropout bandwidth is fixed at 596 wider than the pickup band The pickup and drop out bands are centered about the nominal fre quency Atime delay is also included and i adjust able from 1 15 seconds Time Delay Module The time delay module plugs intothe J2 edge con nector on the motherboard The time delay module contains the timing circuits and associated logic that provide time delays fongenerator starting load transfer load retransf r and generator stopping The Source Available o tput signals are received from the voltage sensors If the Source 1 Available signal is interrupted the start time delay begins tim ing out The start time delay adjustable from O to 15 sec onds begins timing if the input signal from the Source 1 voltage sensor is interrupted Ifthe signal 2 5 returns during the timing out period the timer set If the signal does not return by the of the delay period the timer signals for the generator set to start The purpose of this delay is to prevent gen erator set start up when power interruptions of very short duration occur An optional time delay mod ule with a O to 90 second start time delay
36. are completed OPTIONAL OPTIONAL POWER 3 WIRE PROGRAMMED SENTRY START OR TRANSITION CONTROL SIGNAL MODULE INDICATOR LAMPS OPTIONAL METERS OPTIONAL 3 WIRE START OPTIONAL CHANGE OVER CLOCK SWITCHES ACCESSORY CONTROL PANEL MOTOR OPTIONAL AUTOMATIC DISCONNECT BATTERY TRANSFER SWITCH CHARGER SWITCH 5 1581 FIGURE 5 3 GENERATOR SET TO GENERATOR SET TRANSFER SWITCH CABINET INTERIOR Power Sentry Time Delays Start Time Delay This delay is adjustable from 0 to 15 seconds This brief time delay prevents gen erator set starting during power interruptions of short duration Timing starts the moment of power interruption If the duration of interruption exceeds the delay time the control system signals the other generator set to start To set this time delay align the slot on the potenti ometer with the desired marking on the Power Sen try cover Stop Time Delay This delay is adjustable from to 10 minutes It begins timing when the load is retransferred to the other generator set Atthe end ofthe delay the stop signal is sentto the generator set that is no longer connected This time delay al lows the generator set to cool down at no load be fore stopping To set this time delay align the slot on the potenti ometer with the desired marking on the Power Sen try cover Transfer Time Delay This delay begins when generator voltage and frequency reach the settings of the control A
37. cap s and install the capacitor s in the bracket s Use wire ties to hold ctuator lead wires in place Check the operation of the transfer switch and alignment of the actuator rod by manually Opening and closing both the Normal and Emergency switch assemblies Place the plastic switch cover in position and secure with machine screws 4 and flat wash ers 4 Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque If a generator set is the Emergency power source connect the starting battery negative H lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emer gency power source Placethe operation se lector switch in the Auto or Remote position Test the switch for proper operation and close the cabinet ROD END ASSEMBLY GROUND WASHER FIGURE 4 2 LINEAR ACTUATOR 40 TO 125 AMPERES 4 3 BLOCK AND CROSS BAR ASSEMBLY REMOVAL AND REPLACEMENT 40 to 125 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can caus
38. care when disengaging the switch lever from the crossbar to avoid cracking the switch lever 7 Remove the hex head machine screws and nuts that secure the auxiliary switches to the bracket Figure 4 5 and lift out the four auxil iary switches insulating barriers and switch lever 4 7 Replacing Auxiliary Switch Assembly 1 10 Place the auxiliary switch lever in the bracket as shown in Figure 4 5 Note that the end of the lever with the octagonal hole muStefigage the transfer switch cross bar when the auxiliary switch assembly is installed Install the auxiliary switches 4 and insulating barriers 5 in the bracket and secure with hex head machine screwS 2 and nuts 2 Tighten to 10 to 15 in Ibs 17fto 1 7 Nem torque Note that each switch must be assembled so the side with two terminals Figure 4 5 is facing in ward towardithe other auxiliary switch assem bly Manually close the contacts that will be cou pled to the auxiliary switch lever Hold the auxiliary switch assembly in position base and check the alignment of the auxiliary switch lever When the transfer switch assembly is closed the auxiliary switch must be aligned as shown in Figure 4 5 Move the auxiliary lever as required to get the correct alignment Secure the bracket to the base using the hex head machine screws and tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque Install control wiring leads on the
39. controls transfer switch position only when the Local Remote switch is in the Local position Local Remote Switch Local Remote Switch is used to enable the Nor mal Standby Switch Local position or the remote control inputs at TB2 Remote position STANDBY CONNECTED LAMP STANDBY AVAILABLE LAMP OPTIONAL AC VOLTMETER OPTIONAL AC AMMETER OPTIONAL FREQUENCY METER NORMAL STANDBY SWITCH FIGURE 7 2 NONAUTOMATIC REMOTE CABINET WITH OPTIONS Optional Meter Package The optional meter package includes an AC amme ter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltage of the selected power source AC Ammeter The ammeter measures the line currents of the load Frequency Meter This meter measures the out put frequency of the selected power source in hertz Phase Selector Switch This switch is used to se lect the source and phase to be measured On transfer switches with an AC ammeter the source wires must each pass through a current transformer TRANSFER SWITCH The transfer switch Figure 7 3 opens and closes the contacts that transfer the load between Normal and Standby power The transfer switch is me chanically interlocked to prevent simultaneous closing to both power sources The main parts of the transfer switch discussed here are the contact assemblies linear actuator Motor Disconnect switch and auxiliary
40. dry wood platforms concrete floors when working on any electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling any electrical equipment Jewelry is a good conductor of electricity and should be removed when working on the electrical equipment Do not work on this equipment when mentally or physically fatigued or after consuming alcohol or any drug that makes the operation of equipment unsafe OT3 UG 3 1 Introduction ABOUT THIS MANUAL This manual contains service procedures for an OT transfer switch Sections 1 2 3 and 4 cover the utility to generator set automatic transfer switch Although much of the information on theory of op eration Power Sentry calibration and trouble shooting in sections 1 2 and 3 is applicable to gen erator set to generator set utility to utility and nonautomatic remote configurations there are several significant differences Refer to section 5 for an overview of the generator set to generator set transfer switch Refer to section 6 for an overview of the utility to utility transfer switch Refer to section 7 for an overview of the non automatic remote transfer switch Refer to the schematic and wiring diagram package that was shipped with the transfer switch for spe cific information about its configuration Section 4 of this manual covers transfer swit has sembly service procedures for all con
41. energizes the nor mally energized two wire start relay K 11 lights the Start Gen Set lamp dimly and if applicable sends a start signal to the 3 Wire Start module On two wire start systems K11 contacts close and signal the generator set to run On three wire start systems a relay in the 3 Wire Start module signals the generator set to run The Start Gen Set lamp remains lit as long as the control is signaling the generator set to run Source 2 Voltage Sensor The Source 2 voltage sensor monitors the voltage output from the gen erator set When the voltage rises above the pickup setting the sensor signals that the Emer gency power source is available The Source 2 Available lamp lights and stays on as long as the Emergency power source is within the voltage and frequency settings of the voltage sensor Transfer Time Delay The transfer time delay be gins timing as soon as the voltage sensor signals that source 2 voltage is available The transfer time delay is adjustable from O to 120 seconds The Transfer Timing lamp lights to indicate that the transfer time delay is timing This pause before transferring the load to the generator is to allow the generator set to stabilize Transfer of Load After the transfer time delay has timed out the time delay module sends out a trans fer signal If the optional Signal Module is not used thetransfer signal energizes the transfer control re lay K14 If the Signal Module is used
42. if equipped expired 4 5 Standby source voltage present Check the Standby Available lamp Check the Standby source voltage 5 Manually transfer the switch see Operation 7 8 Transfer Switch Does Not Retransfer To The Normal Source 1 Check the Motor Disconnect switch It sho ld be in the Auto position 2 Are the Local Remote and Normal Standby switches the correct positions Has the programmed transition time delay if equipped expired Is the Normal source voltage present Check the Normal Available lamp Check the Normal source voltage 5 Manually retransfer the switch see Opera tion 8 Schematics SCHEMATIC PAGE Mother Board 300 3953 Utility to Generator Set 8 3 Mother Board 300 3267 Utility to Utility Genset to Genset N 8 4 Mother Board 300 3090 Utility to Generator Set Tees 8 5 626 1762 Sheet oso eos pus ee MURS pde ees AP prr 8 6 626 1762 5 2045 nae 8 7 626 1762 Sheet 3of5_ 22 22 22 8 8 626 1762 ee una dide Peu 8 9 626 1762 Sheet5of 5 Chere eer 8 10 Open Construction Wiring Diagrams S N Q gt 8 1 3 CONNECTED K15 3 LIGHT 1 17 8 K10 1 K12 2 10 2 2 4 ISER LOCAL J4 SOURCE
43. is in effect local or remote se lection of Normal power will cause retransfer to the Normal power source if the Normal power source is available Refer to sheets 1 2 and 5 of your schematic and wiring diagram package Auxiliary Relays Option Optional auxiliary relays provide contacts for ener gizing external alarms remote indicators and con trol equipment such as Iduver motors and water pumps Connections to the auxiliary relays are made di rectly to the relay terminals The terminals accept wire sizes 18 AWG wire to two 12 AWG wires All relays have two normally open and two normally closed contacts that are rated for 6 amperes at 600 VAC Figure 7 5 Table 7 1 lists several auxiliary relay options The felays are energized by the same signals that power the corresponding indicator lamps on the cabinet door Refer to sheet 1 and to the drawings referenced on Sheet 3 of your schematic and wiring diagram pack age 5 1573 38 on Q FIGURE 7 4 REMOTE CONTROL CONNECTIONS TABLE 7 1 AUXILIARY RELAY OPTIONS 24 VAC Coil 24 VAC Coil 24 VAC Coil 24 VAC Coil 24 VAC Coil Installed Not Wired Emergency Connected Relay Normal Connected Relay Emergency Source Available Relay Normal Source Available Relay SC1576 FIGURE 7 5 AUXILIARY RELAYS Programmed Transition Option The optional Program Transition module Figure 7 6 is used to introduce a pause durin
44. or 24 VDC The 2 ampere battery charger has an ammeter to indicate charging current and a fuse to protect the battery charger circuit The 10 ampere battery charger has three fuses two on the AC input and one on the DO output three fault display LEDs and an ammeter _fonindi cation of charging current On the 10 ampere charger three sets of form C alarm contacts corresponding to the three fault LEDs are also available These contacts can be wired by the installer to activate other audible or vis ual alarms Under normal operating conditions the Low Bat and AC Fail relays are energized and the High Bat relay is de energized to a Low Bat AC Fail condition the appropriate normally ener gized relay Low Bator AG Fail drops out In re sponse to a High Bat condition the normally de en ergized High Bat felaysis energized The alarm contacts are rated for 4 amperes at 120 VAC or 30 VDC Connections to these contacts are made atterminals 41 42 43 AC failure 44 45 46 high battery voltage and 47 48 49 low battery voltage of TB3 Figure 5 1 1 Refer to sheet 2 of the schematic and wiring dia gram package The high and low alarm and float voltage adjust ments are set at the factory Adjustment proce dures are described in section 2 P BATTERY CHARGER TAM 12 24 VOLT ES1692 SC1613 2 AMP 10 AMP CHARGER CHARGER kjo une 1 FAILURE eell
45. personal Injury death and or equipment damage Therefore all cor rective service procedures must only be performed by technically qualified personnel following the procedures provided in this manual The transfer switch presents a shock hazard that can cause Severe personal Injury or death unless all AC powers removed Be sure to move the generator set operation selector switch to Stop disconnect AC line power disconnect the battery charger 5 source and dis connect the starting battery negative lead first before servicing Ignition of explosive battery gases can cause Injury Do not smoke or cause any spark arc flame while servicing batterles TABLE 1 1 ANNUAL PREVENTIVE MAINTENANCE 1 DISCONNECT ALL SOURCES OF AC POWER Disconnect both AC power sources from the transfer Switch before continuing If a generator set pro vides Emergency power turn the operation selector Switchito Stop The selector switch is located on the generator set control panel If there Is an external battery charger disconnect It from Its AC power source Then disconnect the set starting battery negative lead first 2 CLEAN a Thoroughly dust and vacuum all controls meters switching mechanism components interior buswork and connecting lugs b Close the cabinet door and wash exterior surfaces with a damp sponge mild detergent and water Do not allow water to enterthe cabinet espe
46. power to the time delay module from the time Normal power is lost until Emergency power is available Refer to Control System Operation Additional inputs to the utility to generator set mother board include e Test exercise inputs Manual retransfer input Transfer inhibit input Instant retransfer input Delayed transfer and retransfer inputs test exercise inputs fromsthe Test Normal Retransfer switch and from optional exerciser clock are used to start the generator set Their function is described underControl System Opera tion in this section Closure of a set of contacts across the remote test transfer inputs terminals 7 and 8 of TB2 causes the transfer Switch to sense a simulated utility power failure nd send a start run signal to the gen erator set The load is transferred to the generator set when generator set power becomes available On 300 3090 mother boards the With Without Load switch must be in the With Load position On 300 3953 mother boards this input Is NOT depend ent upon the position of With Without Load switch The manual retransfer input from the optional Auto Manual switch blocks automatic retransfer and permits only manually initiated retransfer 2 3 The Transfer Inhibit input when 5 Emergency power from being sensed This input is at terminals 5 and 6 of TB2 The Instant Retransfer input from the Test Normal Retransfer switch is optically coupled
47. range is also available The utility to utility transfer Switch has no start time delay The transfer time delay adjustable from O to 120 seconds begins timing as soon as the Source 2 voltage sensor Signals that power is available At the end ofthede lay the timer signals for the load to transfer to the generator set The purpose of the delay is to allowthe generator setto stabilize before the load is applied When they Source 1 power returns and Source Available signals are received from both voltage sensors the time delay module will respond to the preferred source In utility to generator installa tions Source 1 is recognized as the preferred source In utility to utility or generator to generator installations the preferred source is selected by setting an externally mounted selector switch The retransfer time delay adjustable from O to 30 minutes begins timing as soon as the input signal from Source 1 voltage sensoris sentto the time de lay module At the end of the delay the timer sig nals for the load to transfer to the normal source The purpose of the delay is to allow the normal power source to stabilize before the load is applied The stop time delay adjustable from 0 to 10 min utes begins timing as soon as the retransfer timer signals for the load to transfer to the normal source Atthe end ofthe delay the timer signals for the gen erator setto stop The purpose of the delay is to allow the generator se
48. se vere personal Injury or death by fire or ex plosion Do not permit any flame cigarette spark pilot light arcing equipment other possible source of Ignition near the fuel system Generator Set Scheduled For Duty Cycle Starts But Does Not Assume Load 1 Has the transfer retransfer time delay expired 2 Check the generator set output voltage by ob serving the voltmeter on the generator set or the optional voltmeter on the automatic trans fer switch Open the cabinet door and check to see if the Motor Disconnect switch is in the Auto position AC power within the cabinet and the rear side of the cabinet door pre sents a shock hazard that can cause severe personal Injury or death For this reason do not touch or allowclothing tools orjew elry to contact exposed electrical terminals whenever the cabinet door 15 open Make sure you are standing on dry Insulating surface 5 16 4 Check the appropriate Source Available lamp on the Power Sentry 5 Manually transfer the switch see Operation Generator Set Continues To Run After Completing Duty Cycle 1 Check the position of the generator set opera tion selector switch It should be in the Auto 3 wire start or Remote 2 wire Start position 2 The stop time delay function not have ex pired Check the Stop Timing lamp on the Power Sentry If the timer is defective stop the generator set with itS Start Stop switch Battery Charger Fails T
49. supplies the electrical load with power from one of these two power sources The load is con nected to the common the transferswiteh Figure 6 1 Under normal conditions the load is supplied with power from the Normal soufce as illustrated If the Normal power sourcetis interrupted the load is transferred to the Emergency power source When Normal power retums the load is retransferred to the Normal power source The transfer and retransfer ofthe load are the two most basic functions transfer switch Utility to Utility Transfer Switches Utility to utility transfer switches capable of auto matic operation without operator involvement per form the following basic functions 1 Sense the interruption of the Preferred power Source 2 hransfer the load to the Backup power source 3 Sense the return of the Preferred power Source 4 Retransfer the load to the Preferred power source 6 1 SOURCE 1 SOURCE 2 FIGURE 6 1 LOAD TRANSFER SWITCH TYPICAL FUNCTION CABINET The standard cabinet meets the requirements of the National Electrical Manufacturers Association NEMA for a UL Type 1 cabinet This type is desig nated as a general purpose indoor cabinet Items on the door of atypical cabinet are shown in Figure 6 2 Indicator Lamps There are four indicator lamps on the cabinet door The Source 1 Available and Source 2 Available lamps are lit whenever their corresponding power sources are pr
50. switches control transfer of the load to the Normal source 1 power source or to the Emergency source 2 power source without oper tor involvement GENERATOR SEL1 GENERATOR SET 2 FIGURE 5 1 LOAD TRANSFER SWITCH TYPICAL FUNCTION CABINET The standard cabinet meets the requirements of the National Electrical Manufacturers Association NEMA for a UL Type 1 cabinet This type is desig nated as a general purpose indoor cabinet Items on the door of atypical cabinet are shown in Figure 5 2 Indicator Lamps There are four indicator lamps on the cabinet door The Source 1 Available and Source 2 Available lamps are lit whenever their corresponding power sources are producing power These two lamps can be lit simultaneously The Source 1 Connected and Source 2 Connected lamps indicate which power source is connected to the load Only one of these two lamps can be lit SOURCE 1 CONNECTED LAMP SOURCE 1 AVAILABLE LAMP PHASE SELECTOR SWITCH FOR OPTIONAL METERS Source Selector Switch This is a three position switch In the Auto position the optional change over clock determines which generator set has priority to run and assume load Transfer and retransfer are con trolled by the change over clockand in the event of a generator set fault the voltage sensing and tim ing components of the electronic control system In the Source 1 position the Source 1 generator set has priority to run and ass
51. the capscrews to 70 to 75 7 9 to 8 5 Nem black actuator lead wire to the cir Cuit breaker and the red and white actuator lead wires to the following capacitor terminals Wire Connectto capacitor C 1 Ter minal 1 White Lead Wire Connect to capacitor C2 Terminal 2 Transfer switches for voltage ranges 347 380 416 and 440 480 use two capacitors C1 and C2 wired together In serles single jumper wire Is placed between terminal 2 on C1 and terminal 1 on C2 Transfer switches for voltage ranges 115 190 200 208 and 220 240 use two capacitors C1 and C2 wired parallel Two jumper wires are used One Is placed between terminal 1 on and terminal 1 on C2 The otheris placed be tween terminal 2 on C1 and terminal 2 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 ac tuator Use wire ties to hold the actuator lead wires in place with the rest of the wiring har ness Place the plastic switch covers in position and secure with machine screws and flat washers Tighten to 25 to 30 2 8 to 3 4 Nem torque m ab tees ACTUATOR ROD c9 WARNING LINEAR ACTUATOR 20 lt 2 ACTUATOR CAPSCREW EMERGENCY APSCREW ACTUATOR J C SPACER t 5 2 2
52. the transfer switch is in the Emergency posi tion arid the Emergency source is energized K16 is en rgized by the action of position sensing auxil iaryswitch 57 When K16 is energized its run inter lock contacts K16 2 K16 4 are open preventing being re energized This prevents the control from stopping the generator set as long as it is still powering the load 2 21 As the generator set runs and produces power at an acceptable voltage and frequency th Source 2 Available lamp lights and the source 2 relay K12 is energized openifig contacts K12 2 K12 4 If the generator set fails during test or exercise these contacts close to initiate retrans fer to Normal power Note that with the transfer switch the Emergency position contacts K10 2 K10 4 are closed End of Test Exercise The test exercise period is stopped by test or exercise signal This is done by moving the Fest Normal Retransfer switch to Normal by the remote test Switch or automatically by the opening of con tacts in the exerciser clock If thetest exerclse was conducted without load then the femoval of the ground signal from K13 causes 1 to be de energized closing contacts K13 2 K43 47 The closure of these contacts ener gizes two wire start relay K11 which removes the two wire gt start signal and if applicable sends Stop Signal to the 3 Wire Start module If the tesUexer
53. to make cert ln that you Install new block assemblies thelr correct positions Fill the insulator cups that cover and insulate the block assembly mounting screws with ad hesive silicone to completely cover the wash ers and screw heads Install the power source supply wires and se curely tighten the lugterminals to 10 to 12 ft Ibs 13 6 to 16 3 Nem storque Connect the control wiring leads to the power source termindls Gontrol wires are marked NORM EMER A B C for identification Apply a thif coatof electric joint compound be tween mating surfaces of the jumper bus bars the braided strap connectors and load bus bars Install th jumper bus bars and secure to the switch assemblies with hex head capscrews spring washers and bushings The neutral pole on 4 pole switches does not have a bush ing at this connection Tighten to 18 to 20 ft Ibs 24 4 to 27 1 Nem torque Secure the jumper bus bars to the load bus bars with hex head capscrews ring terminals and spring washers Tighten to 10 to 12 ft Ibs 13 6 to 16 3 Nem torque Connect the control wiring leads to the jumper bus bars Control wires are marked LOAD for identification Apply thread sealant blue Loctite 242 Onan part number 518 0309 is recommended to the threads of the interlock bar capscrews Install the interlock bar and secure to each interlock arm with a hex head capscrew lock washer and flat washe
54. to sheets 2 4 and 5 of your sche matic and wiring diagram package Terminal block TB1 Figure 2 3 provides the con nection terminals for form C auxiliary switch con tacts Referto sheet 1 of your schematic and wiring diagrams package Terminal block TB2 on the utility to generator transfer switch provides the connection terminals for two wire start transfer inhibit and remote test Refer to sheet 1 of your schematic and wiring dia gram package Refer to section 5 6 or 7 If applicable Terminal block TB3 Figure 2 3 provides the con nection terminals for the 3 Wire Start 4 Shed battery charger alarm contacts and Sigr al Module Y32232 A T rre ur options Refer to sheet 1 of your schematic and wir ing diagram package and to Optional Control Mod ules and Accessories Open Construction On open construction configurations indicator lamps and key switches are connected to TB3 Re ferto sheet 1 of your schematic and wiring diagram package and to the Open Constr ction Wiring Dia grams sheet in Section 8 OPTIONAL CONTROL MODULES AND ACCESSORIES Optional Control Modules include e 3 Wire Start e Program Transition e Signal Module e Exerciser clock Uutility to generator set trans fer switch Change over clock generator set to genera tor set transfer switch e Phase Sequence Balance Monitor e Standby Set Start Sequencer generator set to generator set transfer sw
55. to the actuator rod Remove the rod end assembly from the actua tor rod Figure 4 2 and slide the rod out of the actuator Replacing Actuator 1 Insertthe actuator rod into the replacement ac tuator motor from the side opposite the ground brush Figure 4 2 Install the rod end assem bly and tighten the capscrew to 70 to 75 in Ibs 7 9 to 8 5 Nem Position the actuator motor on the blocks semblies so the load wires are at the bottom and fit the rod assembly into the handle of the closed switch assembly Secure the actuator motor to thesblock blies using socket head capscrews 4 and lock washers 4 Be 4 rec nnect the ground wire to the lower leftscrew Figure 4 1 Tighten capscrews to 2540 3O in Ibs 2 8 to 3 4 Nem torque ACTUATOR CAUTION Do not overtighten screws orthe switch can be damaged Connect the black actuator lead wire tothe cir cuit breaker and connect the red and white ac tuator lead wires to the following capacitor ter minals Red Lead Wire Connect to capacitor C1 Ter minal 1 White Lead Wire lf capacitor connect to capacitor C1 Terminal 2 If two capacitors connect to capacitomC2 Terminal 2 Transfer switches for voltage ranges 347 380 416 440 480 480 use two capacitors C1 and C2 wired together In series single jumper wires placed between terminal 2 on C1 and Terminal on C2 the capacitor end
56. with the generator set running and the Test switch in the Test position 11 Place the Signal Module Delay No Delay switch back in the Delay position Go to step 12 12 Is there approximately 24 VAC between J7 4 the mother board and ground 13 Is there approximately 24 VAC between J7 5 on the mother board and ground 14 Replace the mother board and recalibrate the voltage Sensors 15 Is there approximately 24 between T2 X1 and and 2 2 located on the accessory control panel 16 Either switch S7 located on transfer switch assembly is defective or there is an open in the wiring from transformer 2 1 to J7 5 on the mother board 17 Is there line voltage on the primary side Of T2 on the accessory control panel 18 Either the connection at 245 bad or the transformer itself is bad Replace the transformer or repair the wiring 19 If there is generator voltage dt the Emergency lugs of the transfer switch then there is an open in the wiring from the Emergency lugs Phase A and B to the primary side of T2 20 Unplug P2 while watching K2 Does the relay drop out 21 Either relay K2 on the acee ssory control panel is defective or there is open in the wiring from J7 4 to K2 A 22 There may b an open between K2 9 or K2 7 and the linear motor The cir cuit breaker CB1 can be open or defective or the linear motor could be defective Both are located on the
57. 1 MOD 003 TRANSFER 3 RETRANSFER J8 lai 95 2 3 WIRE 300 3090 MODIFIED START 328 J7 to TO TRANSFER SWITCH SAFETY BEN ET INTERLOCK 12 5 20 28 2 CR8 A 104804 3 4004 ne OA mI 2 toe IS nts OF OF op XFER INHIBIT J8 6 12 10 sI OvDC CR30 CR29 lt 4004 004 2 CR34 CR33 POWER gt 45 SIGNAL MOD oe 2 POWER eels I 2 3 wIRE 11 l 1 4 i 17 55 REXFR OUT 3 SIGNAL MOD 2 063 J4 3 6 TRANS OUT Os SIGNAL MOO 003 _ START 12 GEN SET 2 3 wiRE 24 10 TRANS IN SIGNAL MOD J4 J5 COM COM SIGNAL MOD 2 3 WIRE J4 3 RExFR IN SIGNAL MOD Ki2 44 _ START lt 12 GEN SEA SIGNAL MOD 13 247 SOURCE 2 AVAIL J4 SOURCE FAIL 3 SIGNAL MOU SIGNAL MOD 003 3 2 3 WIRE ES1973s S z L33HS 2971 929 NA NB NC T84 4 E Pici T a Pte 1 3 B1i i 11 4 T A TO S13 A H4 HX AAA N hua V HZ SENSING 5 MS lt i k YT xo RETRANSFER Test 97 8 R 24 VAC TRANSFER 7 7 7 6 512 TEST NORMAL RETRANSFER SWITCH X CLOSED MOMENTARY 054 NORMAL POSITION LIGHT K1 TRANSFER TO NORMAL RELAY TP7 MS OPT EXERCISE CLOCK DS3 NORMAL SOURCE A
58. 35 Cathod CR37 Cathode and CR39 Cathode Is there approximately 12 VDC between the CR28 anode on the mother board and ground Withthe voltage sensor removed from slot J3 on the mother board is there 15to 25 VDC between 43 14 J3 15 J3 16 and ground and 20 to 30 VDC be tween J3 17 and ground If voltages are OK put the board back in slot J3 If the sensor module is equipped with frequency sensing is the frequency within limits 5 5 If it can t be calibrated then replace the sensor and calibrate the new one Find open in the wiring between the Emergency lugs the transfer Switch and the transformer assembly terminal block located below the mother board Replace the mother board and recalibrate the voltage sensors Rerform these steps in the following sequence A Replace the ribbon cable B If source 2 voltage is not sensed replace the transformer assembly and recalibrate the voltage sensors C If source 2 voltage is not sensed replace the mother board and recalibrate the voltage sensors AC power within the cabinet and the rear side of the cabinet door presents shock that can cause severe personal Injury or death The following procedures are to be performed only by technically qualifled personnel Use extreme caution to avold touching electrical contacts when the cabinet door is open Remove power to the door by disconnectin
59. 4 1 1 to the base Move the terminal bracket to allow access to the base Remove the control wiring leads from the auxil iary switch terminals Figure 4 15 Close the transfer switch to the side you are working on and remove the hex head machine screws that secure the auxiliary switch assem bly bracket to the base 6 Lift out the auxiliary switch assembly Remove the hex head machine screws and nuts that secure the auxiliary switches to the bracket Figure 4 15 and lift out the auxiliary switches and insulating barriers Replacing Auxiliary Switch Assembly 1 Install the insulating barriers 5 and auxiliary switches 4 in the brackets and secure with hex head machine screws 2 nuts 2 Tighten to 10 to 15 in Ibs 1 1 1 7 Nem BARRIERS TORQUE TO 10 TO 15 IN LBS 1 1 TO 1 7 Nem Note that each switch must be assembled so the side with two terminals faces inward Fig ures 4 13 4 14 and 4 15 when the auxiliary switch assembly is installed on the b se Hold the auxiliary switch assembly in position on the base the side with two terminals must face inward and secure the bracket to the base with the hex head machine screws Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem Install the control wiripng leads on the corre sponding switch terminals Leads are marked with the terminal numbefs S2 NO S5 NC 7 etc for identification Refer to figures 4 13 4 14 ande
60. 4 TSefor identification of the auxiliary switch terminals Place the terminal bracket in position on the base and secure it with the hex head machine screws Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem Place the plastic cover in position and secure withathe hex head screws and flat washers Tighten to 25 to 30 2 8 to 3 4 Nem a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emer gency power source Place the operation se lector switch in the Remote position Test the transfer switch for proper operation and close the cabinet NO COM FIGURE 4 15 AUXILIARY SWITCH 300 TO 600 AMPERES 4 24 LINEAR ACTUATOR REMOVAL AND REPLACEMENT 800 and 1000 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal Injury or death Disconnect all sources of AC power from the transfer switch before servicing
61. 7 If applicable Test Normal Retransfer switch Normal position Motor Disconnect switch Auto position Operation selector Switch engine control Remote position Iwo wire start for water cooled generator set only Stop Auto Handcrank switch Auto position Three wire start for air cooled gen erat r sets Manual Operation Thetransfer switch has operator handles for manu ally transferring the load Use the following proce dure AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death Use extreme cautlon to avold touching electrical contacts whenever the cabinet door 15 open If possible remove all AC power to the transfer switch before manually operating the switch If It Is necessary to perform manual operation with AC power connected follow the Safety Related Work Practices listed 70 1 Open the cabinet door of the automatic trans fer switch 2 Move the Motor Disconnect switch to the Off position 3 Transfer from the Normal to the Emer gency power source A Pull the upper manual operator handle down B Push the lower manual operator handle down Retransfer from the Emergency to the Nor mal power source C Pull the lower manual operator handle up D Push the upper manual operator handle up 4 Before moving the Motor Disconnect switch back to the Auto position remember the trans fer switc
62. CH COVER 300 TO 600 AMPERES 4 18 7 Check the operation of the transfer switch 9 generator set is the Emergeneyapower the alignment of the Actuator rod by manually source connect the starting battery negative opening and closing both the Normal and lead last If applicable connectthebattery emergency switch assemblies charger to its AC power source Reconnect the Normal power source Emer 8 Install the plastic switch cover on the switch gency power source Place the operation se with the four screws Tighten to 25 to 30 in Ibs lector switch in the Remote position 2 8 to 3 4 Nem 10 Test the switch for prop r operation and close the cabinet FIGURE 4 12 ACTUATOR 300 600 AMPERES 4 19 BLOCK AND CROSS BAR ASSEMBLY REMOVAL AND REPLACEMENT 300 to 600 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal Injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the rem
63. Connect the control wiring leads to the corre sponding jumper bus bar terminal Control wires are marked LOAD A B C for identifica tion INTERLOCK BAR lt Se ZI T eto TN 4 58 JUMPER 1 JUMPER BUS BAR LOAD BUS BAR TORQUE TO 25 TO 30 IN LBS 2 8 3 4 Nem S yTORQUE TO 15 TO 20 IN LBS 1 7 TO 2 3 Nem FIGURE 4 3 SWITCH ASSEMBLY 40 TO 125 AMPERES 4 5 POWER SOURCE LEAD TERMINAL CONTROL WIRING TERMINAL FIGURE4 4 CONTROL WIRING TERMINALS 40 TO 125 AMPERES 10 Apply thread sealant blue Loctite 242 Onan 11 part number 518 0309 is recommended to the threads of the interlock bar machine screws Install the interlock bar and secure to each in terlock arm with a round head machine screw and flat washer Tighten to 15 to 20 in Ibs 1 7 to 2 3 Nem torque Attempt to close both sides of the transfer switch The interlock assembly must hold one side open so that only one side closes at at time 4 6 12 13 Replace the linear actuator as described in Linear Actuator Removal And Replacement section for 40 to 125 ampere switches Follow steps 2 through 8 in the Replacing Actuator section Apply a thin coat of lubricant Onan part number 524 0157 to the slot in the han dle Test the switch for proper operation and close the cabinet AUXILIARY SWITCH
64. ED LAMP SOURCE 2 AVAILABLE LAMP OPTIONAL AC VOLTMETER OPTIONAL AC AMMETER OPTIONAL FREQUENCY METER SOURCE SELECTOR SWITCH FIGURE 6 2 UTILITY TO UTILITY CABINET WITH OPTIONS Optional Meter Package The optional meterpackage includes an AC amme ter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltage of the selected power source AC Ammeter The ammeter measures the line cur rents of the load Frequency Meter This meter measures the out put frequency of the selected power source in hertz Phase Selector Switch This switch is used to se lect the source 1 or 2 and phase to be measured On transfer switches with an AC ammeter the load wires must each pass through a current trans former TRANSFER SWITCH The transfer switch Figure 6 3 opens and closes the contacts that transfer the load between source 1 and source 2 power The transfer switch is me chanically interlocked to prevent simultaneous closing to both power sources The main parts of the transfer switch discussed here are the contact assemblies linear actuator Motor Disconnect switch and auxiliary contacts Contact Assemblies The automatic transfer switch fas either three or four poles Three pole transfer switches are pro vided with a neutral bar The contact assemblies make and break the current flow When closed to either the Normal or the Emerg ncy pow
65. GURE 4 20 AUXILIARY SWITCH 8004 1000 AMPERES 4 33 5 GenSet to GenSet INTRODUCTION This section provides information for a transfer switch with an automatic generator set to genera tor set control Much of the information on theory of operation Power Sentry calibration and troubleshooting in sections 1 2 and 3 is applicable Refertothis sec tion 5 for an overview of the generator set to gen erator set transfer switch Refer to the five sheet schematic and wiring diagram package that was shipped with the transfer switch for specific infor mation about its configuration Section 4 of this manual covers transfer switch as sembly service procedures for all configurations Transfer Switch Application This transfer switch enables two generator sets running at alternate times to provide power load The transfer and retransfer of the two most basic functions of a transfer switch The transfer switch may be equipped with an op tional change over clock which is programmed to alternately run and connect orie generator set for a selected time and then to run and connect the other generator set for a selected time If one of the generator sets failsto operate within a selected range of voltage and optionally fre quency the transfer switch automatically starts and connects the oth r gen rator set Figure 5 1 shows generator set number 1 con nected to the load Automatic transfer
66. Ibs 2 8 to 3 4 Nem torque Installthe control wiringleads on the switch ter minals The 5 marked with the termi nal numbers 52 0 S5 NC S7 C etc for identification Refer to figures 4 18 4 19 and 4 20 for identification of the auxiliary switch ter minals Place the terminal bracket in position on the secure it with the hex head machine ScrewS 4 Tighten to 25 to 30 2 8 to 3 4 Nem torque the plastic covers in position and secure them with machine screws and flat washers Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque Insertthe actuator rodinto the replacement ac tuator motor Hold the actuator ground brush up slightly to allow passage ofthe actuator rod Secure the rod end assembly to the actuator rod with the hex head capscrew flat washer and lock washer Tighten the capscrew to 70 to 75 in Ibs 7 9 to 8 5 Nem torque Fit the rod assembly into the handle of the closed switch assembly If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emer gency power source Placethe operation se lector switch in the Remote position Test the transfer switch for proper operation and close the cabinet NO TORQUE TO 10 TO 15 IN LBS 1 1 TO 1 7 Nem BARRIERS FI
67. Module Option The Optional alarm module Figure 2 13 provides an audible indication that the transfer switch has transferred to the emergency power source A push button on the alarm module provides a means to sllence the hom The Alarm lamp indicates that the transfer switch is inthe Emergency Connected position Ifthe hom is silenced the Horn Silenced lamp will also light Both lamps will stay lit until the transfer switch moves from the Emergency Connected position to the disconnected neutral or Normal Connected position FIGURE 2 13 ALARM MODULE 2 16 CONTROL SYSTEM OPERATION The following text covers the operation of the elec tronic control system in a utility to generator set in stallation 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 TesUExerclse With Without Load Mother Board 300 3090 TesUExerclse With Without Load Mother Board 300 3953 Some of the control commands can be verified by observing the indicator lamps on the Power Sentry Control The mother board schematic Section 8 and your schematic and wiring diagram package will help you follow the operation descriptions Normal Power Source Connected to Load the Power Sentry C
68. Position L203 Aux Relay Genset Start L204 Miscellaneous Clock 7 Day Exerciser J001 Module Signal M001 Module 3 Wire Start M002 Terminal Block 30 Points M003 Monitor Phase 5 M004 Sequencer Stdby Set Start 12V M006 Load Shed From Emergency M007 Module Alarm 008 Sequencer Stdby Set Start 24V M010 Switch Auto Manual Change NOO1 Term Block Batt Chrg Alarms 2 Term Block Source1 2 Rmt Signal 05 Power Connect Bus Stabs 09 Cabinet Cabinet Type 1 8001 Cabinet Type 002 Cabinet Type 4 B003 Open Construction B004 2 Electronic Control System INTRODUCTION The electronic control system includes 1 The voltage sensing and start stop transfer and retransfer timing circuitry of the Power Sentry control 2 The transformers relays switch and connec tors of the accessory control panel 3 The optional control modules and accessories 4 The position sensing switches that monitor and control the operation of the automatic transfer switch 5 The standard and optional lamps meters and switches thatare mounted on the cabinet door These components are described in Section 1 They are also referenced in this section when applicable POWER SENTRY CONTROL T
69. REMOVAL AND REPLACEMENT 150 to 260 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AWARNING AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal Injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the block and cross bar assemblies for 150 to 260 ampere switches Removing the Block and Cross Bar Assembly Normal or Emergency 1 Loosen the lug terminal screws and remove the power source supply wires from the lug ter minals Remove the linear actuator as described in the Linear Actuator Removal and Replacement section for 150 to 260 ampere switches Fol low steps 1 through 7 in the Removing Actua tor section Remove the hex head capscrews lock wash ers and flat washers that sec re the interlock bar to the interlock arms Figures 4 8 and 4 9 and remove the interlock baf Remove the round head machin screws and mounting plate that handle assem bly to the switch assemblypand lift off the han
70. RONIC CONTROL SYSTEM This section describes the standard and optional components of the electronic control system Improper calibration or adjustment of electronic control modules can cause death severe personal Injury and equipment or prop erty damage Calibration and adjustment of these components must be performed by tech nically qualified personnel only Power Sentry calibration and adjustment proce dures are described In section 2 The most important component of the electronic control system is the Power Sentry control Figure 6 3 The Power Sentry includes voltage sensing circuits time delay circuits and control relays There are also several adjustment potentiometers and indicator lamps on the Power Sentry The ad justments must be performed only by qualified service personnel Accidental actuation of the linear motor can cause severe personal Injury Dis able the motor as described below before making any adjustments Place the Motor Disconnect switch Figure 6 3 the Off position when making adjustments Return the switch to the Auto position after ad justments are completed OPTIONAL OPTIONAL POWER SIGNAL PROGRAMMED SENTRY MODULE TRANSITION CONTROL INDICATOR LAMPS OPTIONAL METERS SWITCHES ACCESSORY CONTROL PANEL MOTOR AUTOMATIC DISCONNECT TRANSFER SWITCH SWITCH SC1581 2s FIGURE 6 3 UTILITY TO UTILITY CABINET INTERIOR 6 4 Power Sentry Time Delays Transfer Time Delay Th
71. SHOOTING 3 1 Continued Transfer Switch Does Not Retransfer When Normal Voltage Returns After A Power Outage This procedure Is to be performed with the generator set running and Normal voltage on line 12 If the Signal Module is used check that the ribbon cable frofriJ4 on the mother board to the Signal Module is connected properly Cable is OK then place the Delay No Delay switch on the Signat Moddle in the No Delay position Does the transfer switch retransfer Replace the Signal Module Place the elevator signal Delay No Delay in the Delay posi tion Go to Step 15 Is there approximately 24 VAC between 726 on the mother board and ground Is there approximately 24 VAC between J7 7 on the mother board and ground Replace the mother board and reealibrate the voltage sensors Is there approximately 24 VAC between TI X1 and 2 on the acces sory control panel Either switch S3 on the transfer switch is defective or there is an the wiring from T1 X1 to 7 7 the mother board 5 the correct line voltage present on the primary side of T1 on the acces sory control panel Either the connection atitransformer T1 is bad or the transformer itself is bad Replace th transformer or repair the wiring as required If there is line voltage at the Normal lugs of the transfer switch then there is an open in the wiring from the Normal lugs Phase A a
72. Service Manual OT IlI Transfer Switch 40 to 1000 Amperes Printed in U S A 962 0512 11 92 Table of Contents SECTION TITLE PAGE SAFETY 5 iii 1 INTRODUCTION 4 1 1 About This Manual 1 1 Transfer Switch 7 0 1 1 Automatic Transfer Switches 2 1 2 Model Identification 1 2 Cabinet Reo cmn 1 2 Transfer Switch Assembly 1 4 Electronic Control f 1 4 MEET QKL NC DPA 1 7 Preventive Maintenance 1 9 Removing and Replacing Electronic Control Components 1 10 Feature Description Feature Option 1 11 2 ELECTRONIC CONTROL SYSTEM 2 1 Introduction u u usu rrr eR ERR RA ra 2 1 Power Sentry Control 2 1 Accessory Control Panel and Terminal Blocks 2 7 Optional Control Modules and Acessories 2 8 Control System
73. TERLOCK zie SS eel cure a gj k 3 JUMPER 2 BUS BAR BLOCK ASSEMBLY O BARRIER y CHUTE SPACER ARC 2 ARC CHUTE D TORQUE 15 TO 20 IN LBS 1 7 TO 2 3 Nem 4 TORQUE 28 TO 33 FT LBS 40 0 TO 44 7 Nem 2 TORQUE TO 25 TO 30 IN LBS 2 8 3 4 Nem S TORQUE TO 18 TO 20 BS 24 4 TO 27 1 Nem S TORQUE 70 TO 75 IN LBS 7 9 TO 8 5 Nem 8 TORQUE TO 10 TO 12 FT LBS 13 6 TO 16 3 Nem FIGURE 4 19 4 POLE SWITCH ASSEMBLY 800 1000 AMPERES 4 30 Replacing the Block Cross bar Assembly Normal or Emergency 1 Install the interlock arm on the cross bar as sembly and secure with the round head ma chine screws Tighten the screws to 15 to 20 in Ibs 1 7 to 2 3 Nem torque Apply a thin coat of lubricant Onan part num ber 524 0157 to the slot in the handle Place the handle assembly in position on the switch assembly and secure with the shoulder screws lock washers and locknuts Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem Secure the cross bar assembly to the base with the hex head capscrews 4 lock washers 4 and flat washers 4 Tighten to 70 to 75 7 9 to 8 5 Nem torque Apply a thin coat of glyptol between the arc chute spacers and the arc chute barrier Pla
74. The Overcrank timer s range of adjustment is O to 120 seconds Tosetthe timers align the slots on the potentiome ters with the desired markings on the faceplate Figure 5 6 The Auto Stop Handcrank Switch is located on the 3 Wire Start module This switch is the operation selector switch for a three wire start generator set The three positions Auto Stop and Handcrank function as follows Auto Allows the generator set to start and assume the loadif a poweroutage oc curs This Is the normal operating position Stop Shuts down the generator set and prevents it from starting Use this position when servicing the gen erator set Handcrank Prevents the automatic transfer switch from starting the generator set but allows starting and stopping at the set Use this position for generator set maintenance The three wire start circuit uses TB3 terminals 1 2 3 4 and 5 for unit 2 and terminals 31 32 33 34 and 35 for unit 1 See Figure 5 7 TB3 terminals 1 2 3 and 4 t rmi nals on the source 2 generator set as shown in Fig ure 5 7 With diesel sets that use thespreheat cir cuit terminal 5 on TB3 is connected to t rminal H on the source 2 generator set control TB3 terminals 31 32 33 34 are connected to terminals on the source 1 generator set as shown Figure 5 7 With diesel sets thateuse the preheat circuit terminal 35 on TB3 is connected to terminal on t
75. The exerciser clock is powered by the 24 VAC out put of T1 An internal nickel cadmium battery not replaceable maintains time and program informa tion for 150 hours minimum without external power However clock does not initiate exer cise periods whet is under battery power Refer to sheets 2 and St f your schematic and wir ing diagram package 48 FIGURE 2 7 EXERCISER CLOCK Phase Sequence Balance Monitor The optional phase sequence balance monitor APhase BPhase CPhase Figure 2 8 is connected to A B and C phases of utility power If there is an over or undervoltage a phase reversal a loss of one phase or an unbal anced voltage condition a normally energized re lay drops out closing a set of contacts These relay contacts are wired to the remote test input terminals 7 and 8 of TB2 When the contacts across termi nals 7 and 8 of TB2 close the generator set start transfer of load sequence is initiated Five LEDs indicate normal operation or fault condi tions The Relay Energized LED is lit during normal operation Three potentiometers permit setting the percent of voltage unbalance the normal system voltage and the relay dropout time delay The relay dropout delay applies only to over under voltage and voltage unbalance In the event that a phase reversal or loss of one phase Is sensed relay dropout occurs within 100 milliseconds maximum There Is NO relay dropoutdelay when a phase rever s
76. VAILABLE LIGHT SEE SHEET 3 FOR ALTERNATE WIRING Dy WITH PROGRAMED TRANSLTION OPTION Ci MOTOR RUN CAPACITOR Pi 4 235 23 gt J3 54 NO 1 4 1 CIRCUIT NORM 4 5 14 5 4 7 0 7 2 7 1 i LINEAR MOTOR Je 8 S1 MOTOR DISCONNECT SWITCH a esl 1 I 1 S1 1 1 22 J2 6 CUSTOMER LOAD J2 4 CABLES J3 P3 S8 1 12 oM 9 8 2 N NC 11 E aC A ss s mms U RI Ly I DS4 EMERGENCY SOURCE AVAILABLE LIGHT i NO P2 11 052 EMERGENCY POSITION Ja 10 240 27 902 LIGHT NC P2 12 J2 12 K2 TRANSFER TO I EMERGENCY RELAY I I I I 24 TRANSFER RUN INTALK rT INSTANT 2 REXFER Be MAN REXFR f lux I 17 47 1 e T s m 2971 909 5 z m 9UIVJAMU A LU T84 1 METERS ARE OPTIONAL EA EB X CLOSED CONTACTS 1 THRU 12 ARE MAKE BEFORE BREAK T3 IS USED ON UNITS lt lt OVER 300 VOLTS ONLY e ES L NOTES CABINET GROUND EARTH GROUND EARTH B ALL DE
77. VICES ARE SHOWN DE ENERGIZED AND WITH THE TRANSFER SWITCH CLOSED TO NORMAL A SEE SHEET 3 FOR PRIMARY CONNECTIONS HOLIMS H33SNVHL YNOA SVM 39V oVd WVHOViIG 2JLLVW3HOS OL 43434 ONLLOOHS3T8gnOHI 1 lt V SI SNIHIA L33HS S REAR VLEW OF DOOR DSi Al GNG J7 14 G POWER SENTRY CONTRO 053 053 2 TI X1 EH os 2 5125 e GNO 052 1 42 11 23 4 FOR OF JUMPERS 23 5 23 1 3 3 J3 2 CONTROL PANEL K1 B 2 p oO ES M 2 T x J2 9 L O EOR GND TB4 4 TB4 S TB4 6 J7 10 2 4 TB4 1 184 2 T 4 9 TB4 3 w T1 X1 XI 24 VAC X2 J7 13 SEE SHEET 3 J7 7 1 OR PRIMRRY 2 7 10 5 Hi 51 2 TPB K1 7 i 5 GND m T2 X1 JB 8 6 T 7 5 55 5 J8 3 x1 24 vac x2 38 1 SEE SHEET 3 J8 2 T2 FOR PRIMRRY J8 7 CONNECTIONS 8 5 2 arte RENT 1 1 IN TB4 2 am m m NOTES TP amp THRU TP18 RRE 25 INCH INSULRTED FASTON TERMINALS FOR ACCESSORY CONNECTIONS 211 CUSTOMER CONNECTION TERMINAL BLOCK SEE SHEET 1 FOR DETAILS 626 1762 SHEET 4 OF 5 8 9 THIS IS A REPRESENTATIVE GENERIC SCHEMATIC WIRING DIAGRAM FOR TROUBLESHOOTING
78. able a start signal is sent to the 3 Wire Start module With Load Test Locate contacts K10 2 K10 4 and K18 2 K18 4 These two sets of contacts along with a set of K12 contacts provide the two circuit paths for the phase A B Normal side bridge rectifier at CR16 CR17 The bridge rectifier in tum pro vides a sampling voltage to the Normal side voltage sensor Whenever the transfer switch is connected to the Normal source 1 source relay K10 is energized and contacts K10 2 K10 4 are open Under these conditions contacts K18 2 K18 4 provide the only circuit path for Normal phase 40 the bridge rectifier If the appropriate With Without Load switch S1 S4 is in the With Load position alocalteSt cise signal will energize K18 Because the Remote Test input is connected directly to relay K18 a Re mote Test signal will also energize relay When 18 is energized its norfnally closed con tacts open When contacts K18 2 K 18 4 open Nor mal phase power to the bridge rectifier is cut off and a simulated power failure is sensed With Normal phase A Bspowerto the Normal side voltage sensor interrupted generator set start tim ing begins When the generator set starts and the source 2 voltage sensOmsenses generator set volt age transferofload timing begins After the trans fer timer times out the time delay module sends a signal to relay K14 and transfer of load occurs When
79. age from inductive loads to decay to an acceptable level before transfer is completed The length of time that the transfer switch is in the midposition can be adjusted from 0 to 7 5 seconds or 0 to 60 seconds depending on the timer option The proper adjustment is a function of the load To set the time delay align the slot on the potenti ometer with the desired marking on the faceplate Figure 5 8 If a time delay is desired make sure that the Delay No Delay switch is in the Delay position Refer to sheets 2 and 5 of your schematic and wir ing diagram package Signal Module Option The optional Signal Module Figure 5 9 has one adjustable timer The Elevator Signal delay trols the timing of two events It delays transfer retransfer and energizes the Elevator Transfer Sig nal relay during the delay period This time delay is adjustable over a range of 0 to 50 seconds A Delay No Delay switch permits bypassing the timer delay if it is not needed The timing circuit is started by a transfer or retransfer signal from the time delay module on the Power Sentry mother board While the timer is timing the form C Elevator Sig nal relay is energized and lamp on the Signal Module is lit Atthe end of the time delay the Elevator Signal relay iS and the switch is allowed to transfer retransfer There are two other relays with form C contacts on the Signal M
80. al or loss of phase Is sensed Overvoltage dropout occurs at normal voltage Tio ee FIGURE 2 8 PHASE SEQUENCE e Undervoltage dropout occurs at normal volt BALANCE MONITOR age 10 2 e Dropout time delay range is 2 to 20 seconds e Percent voltage unbalance range is 240 6 on 240 and 480 volt units e Percent voltage unbalance range is 210 895 on 380 volt units Standby Set Start Sequencer The optional standby set start sequencer Figure 2 9 is available and applicable only on a genera tor set to generator set transfergswitch dual standby applications the power cables from two generator sets are connected to the source 1 and source 2 lugs of a generatorsSet to generator set transfer switch whichindurn provides power to the generator set source l gs on a utility to generator set transfer switch The function of the standby set start sequencer is to respond to a remote start signal from the utility to generator set transfer switch by directing a start sig nal from the generator set to generator set transfer switch to the RMT start input of the generator set is selected as the preferred source standby set start sequencer permits normal backup set operation if the preferred active set fails The sequencer also permits normal change over clock initiated operation Refer to section 5 and to the system interconnec FIGURE 2 9 STANDBY SET START tion drawings if applicable SEQUENCER OPTION
81. and time de lay are adjustable over the following ranges Function Adjustment Range Bandwidth 59 to 20 of nominal Delay to 15 seconds To set the pickup bandwidth and time delay align the slots on the potentiometers with the desired markings on the Power Sentry cover Figure 2 14 Time Delay Module Adjustments The time delay module controls the following func tions Start time delay Stop time delay Transfer time delay Retransfer time delay The time delays on the standard time delay module are adjustable over the following ranges Delay Adjustment Range Start O to 15 seconds Stop O to 10 minutes Transfer O to 120 seconds Retransfer O to 30 minutes An optional time delay module has adjustable start delay range of O to 90 seconds To set the time delays alignthe slots on the potenti ometers with the desired markings on the Power Sentry cover Fig re 2 14 Automatic transfer switch opera tion results rapid movement of the manual operator handles presents a hazard of se vere personial Injury Keep hands clear of han dles when switching back to automatic opera tion If there no optional control modules to adjust Motor Disconnect Switch in the Auto posi tion and close the cabinet door 2 24 ADJUSTING OPTIONAL CONTROL MODULES AND ACCESSORIES AC power within the cabinefand the rear side of the cabinet door presents ashock hazard that can cause severe per
82. anel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the block and cross bar assemblies for 800 and 1000 ampere switches Removing the Block and Cross bar Assembly Normal or Emergency 1 Remove the linear actuator as described in the Linear Actuator Removal and Replacement section for 800 and 1000 ampere switches Lift the arc chute covers off the arc chutes Remove the hex head capscrews lock wash ers and flat washers that secure the interlock bar to the interlock arm Figures 4 18 4 19 and remove the interlock bar Disconnect the control wiring leads from the jumper bus bars Remove the hex head capscrews ring termi nals and spring washers that Secure the jumper bus bars Figures 4 18 and 4 19 to the load bus bars Remove the hex capscrews spring washers and buShingsthat secure the jumper bus bars to the switchhassemblies Lift off the jumper bus4bars The neutral pole on the 4 pole switches dogs not have a bushing at this connection R
83. anging the time 2 Press the clock button 1 3 Press the h button 3 to the hourofthe day The clock uses 24 hour military time 4 Press the m button 4 to setthe minutes of the hour 5 Press the 1 7 button 5 to advance the indica tor bar over the desirediday 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 cen ter position The output selector switch has three positions The Off position overrides the program and causes an exercise stop The position overrides the program and causes an exercise start The center position selects pro gram control 2 Press the I O button 2 An I 12 appears in the upper display window The 15 a symbol for start time 3 Press the h button 3 to set the start hour 2 25 FIGURE 2 15 EXERCISER CLOCK 4 Press the m button 4 to set the start minute 5 Press the 1 7 button 5 to advance the indica tor bar 13 from 1 to 7 and backto 1 Foreach day to be selected for exercise press the Q button 7 when the indicator is over the de sired day number 1 represents Sunday To set the exercise stop time 1 Press the I O button 2 An 15 appears in the lower left display window The O is sym bol for stop time Press the h button 3 to set the stop hour Press the m button 4 to set th
84. assembly Disconnect the control wiring leads from the jumper bus bars Remove the hex head capscrews and spring washers that secure the A B and C jumper bus bars to the block and cross bar assem blies Remove the two Phillips head screws 4 12 10 11 12 13 and the two hex head capscrews that secure the load lug support block Carefully remove the jumper bus bar load bus bar load lugssup port block assembly Remove the control wiring leads from the power source terminals On 4 pole switches Figure 4 9 Before the block and cross bar assemblyscan be re moved the neutral block assembly must be loosened and pivoted slightly out of the way A Remove the two machine screws that se cure the arc ch te cover Remove the cover and the arc chute Remove the hiex head capscrew terminal ring spring washer and load lug that se cure the neutral jumper bus bar Remove the neutral jumper bus bar Remove the two Phillips screws and the spacer that secure the source lug side of the neutral block Pivot the neutral block slightly away from the block and cross bar assembly Use care when removing the block and cross bar assembly from the base Care fully disengage the cross bar from the auxiliary switch assembly to avoid cracking the switches D Remove the remaining hex head capscrews that secure the block and cross bar assembly to the base and carefully remove the assem bly
85. cal Test input J7 9 from the Test Normal Retransfer switch 512 3 512 4 e Optional Exerciser Clock input J7 8 or e Remote Test input J8 7 The signal consists of a switch closing to ground A ground at K13 8 energizes K13 the test exercise relay Starting the Generator Set When K13 is ener gized its normally closed contacts open When contacts K13 2 K13 3 open K11 the normally en ergized two wire start relay is de energized and a start signal if applicable is sentto the 3 Wire Start module When contacts 13 6 1 3 7 open one of three paths to the phase A B Normal side bridge rectifier at CR16 CR17 is opened Generator Set Starts As the generator set runs and produces power at an acceptable voltage and frequency the Source 2 Available lamp lights and the source 2 available relay K12 is energized When contacts K12 2 K12 4 open the second of three paths to the phase A B Normal side bridge rectifier is opened These contacts close to initiate retransfer to Normal power if the generator set fails during test or exercise With Without Load With K12 source 2 available relay and K13 test exercise relay energized the only path for phase A B power to the bridge rectifi ers is through switch S1 the With Without Load switch If 51 is closed Without Load position the Power Sentry senses that both sources are available In utility to generator set applications the Power Sentry is configured to prefer Sour
86. ce the arc chute spacers 2 arc chute barrier and arc chute in position on each block assem bly 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 Apply a thin coat of electrical joint compound between the mating surfaces of the block as sembly and the lug terminals Install the lug terminals on the block assemblies and secure with the allen head capscrews Tighten 102810 33 ft lbs 40 0 to 44 7 Nem torque Place each block assembly in position on the base and secure with the hex head edpscrews and flat washers Refer toeFigures 4 18 and 4 19 to determine where spacers are re quired Tighten the capscrews to 70 to 75 in Ibs 7 9 to 8 5 Nem tarque 3 pole switches the A phase block on the Normal side and the C phase block on the Emergency side have a spacer under thelr outer mounting tabs O 4 pole switches the A phase block onthe Normal side and the neu tral block on the Emergency side have this spacer Make certain that you in stall new block assemblles with the Spacers In thelr original positions e The block assemblles are not identical The A and C phase blocks and the neutral block on 4 pole switches are different than the B phase block Refer to the parts manual and the part num 4 31 10 11 12 13 14 15 16 17 18 bers stamped on the replac ment block assemblies
87. ce 1 Notransfer of load occurs If S1 is open With Load position there is no path for phase power to the bridge rectifier power failure although simulated is sensed and transfer of load timing begins After the transfer timer times out the time delay module signals relay K14 and transfer of load as described above occurs When the transfer switch is in the Emergency posi tion and the Emergency source is energized A16 is energized by the action of position sensing auxil iary switch 57 When K16 is energized its run nter lock contacts K16 2 K16 4 are open preventing K11 from being re energized This prevents the control from stopping the generator setas longas it is still powering the load End of Test Exercise The test exercise period is stopped by removing the ground from 13 8 This is done by moving the Test Normal Retransfer switch to Normal by opening the remote test switch or automatically byAh opening of con tacts in the exerciser clock When ground is removed from K13 8 its normally closed contacts closet If the test exercise was con ducted without load then the closure of contacts K13 2 K13 3 energizes two wire start relay K11 which removes the two wire start signal and if ap plicable sends a stop signal to 3 Wire Start module If the test exercise was conducted with load then the closure of contacts K13 6 K13 7 provide a path for A B phase power to the bridge rectifiers T
88. ce Available output signal re mains on until the voltage or frequency goes be yond the dropout limits for longer than the corre sponding dropout time delay Undervoltage sensing is accomplished by sensing all voltage phases but responding only to the low est one Thus all phases must be above the under voltage pick up point before undervoltage pickup will occur while undervoltage dropout will occur when any of the phase voltages fall below the drop out point A fixed dropout time delay 0 5 seconds elapses before the Source Available output re sponds to an undervoltage condition The sensoris calibrated and the undervoltage pickup and drop out points are adjusted with potentiometers refer to Adjusting Power Sentry Modules in this 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 ing the peak of the combined phase voltages so that the sensor essentially responds to the highest phase The sensor is calibrated and the overvolt age limit is adjusted with potentiometers refer to Adjusting Power Sentry Modules in this section The overvoltage adjustment range is 105 to 135 of the nominal voltage The pickup point is fixed at 5 below the overvoltage limit point and is not adjustable A time delay is also included and is adjustable from O to 120 seconds Over underfrequency sensing is
89. cially at meters lamps and switches 3 INSPECT a Check buswork and supporting hardware for carbon tracking cracks corrosion or any other types of deteriorationalf replacement is necessary call your dealer or distributor b Check stationary and movable contacts If contact replacement is necessary the procedures are described in section 4 of this manual c Check system hardware for loose connections Tighten as indicated in step 4 d Check all control wirihg and power cables especially wiring between or near hinged door for signs of wear or deterioration e Check all control wiring and power cables for loose connections Tighten as indicated in step 4 f Checkethe cabinet interior for loose hardware Tighten as indicated in step 4 4 PERFORM ROUTINE MAINTENANCE a Tighten buswork control wiring power cables and system hardware as necessary Hardware torque values are given in section 4 of this manual Retorque all cable lug connections Lug torque requirements are listed in Table 1 2 b Service or replace the batteries 5 CONNECT AC POWER AND CHECK OPERATION Connect the set starting battery negative lead last Connect the normal AC power source enable the backup power source If applicable connect power to the battery charger b Verify proper operation of the battery charger c Test system operation as described in this section Close and lock the cabinet door REMOVING AND REPLACING ELECTRONIC CONTROL COMPONENTS
90. cing the Motor Disconnect switch on the Accessory Control Panel in the Auto posi tion Place the Source Selector switch in the desired po sition Manual Operation The transfer switch has operator handles for manu ally transferring the load Use the following procedure AC power within the cablnetand the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death Use extreme caution to avold touching electrical contacts whenever the cabinet door Is open If possible remove AC power to the transfer switch before manually operating the switch If It Is necessary to perform manual operation with AC power connected follow the Safety Related Work Practices listed In 70 1 Open the cabinet door of the automatic trans fer switch Move the Motor Disconnect switch to the Off position Transfer from the Normal to Emer gency power source A Pull the upper manual op rator handle down B Push the lower manual operator handle down Retransfer from the Emergency to the Nor mal power source C Pull the lower manualo perator handle D Push the pper manual operator handle up Before moving the Motor Disconnect switch back to the Auto position remember the trans fer switch will transfer load to the active power source if both power sources are available it will transfer the load to the preferred source 2 Automatic transfer switch Op
91. cise was conducted with load then the removal of the ground signal from K18 Causes K18 to be de energized closing its nor mally open contacts The closure of contacts K18 2 K18 4 provides a circuit path for A B Normal phase powerto the bridge rectifiers This allows the source 1 sensor to sense Normal power and begin retransfer timing After the retransfer delay has timed out the time delay module signals relay K15 and retransfer to the Normal power source occurs After retransfer K16 is de energized closing contacts K16 2 K16 4 The closure of these contacts com pletes the circuit to K11 After the stop time delay times out the time delay module sends a stop sig nal from J2 13 through contacts K13 2 K13 4 and K16 2 K16 4 to the coil of K11 This signal termi nates the start signal Instant Retransfer When testing with load you can bypass the retransfer delay by moving the Test Normal Retransfer switch to the Retransfer position The closing of contacts 512 1 512 2 sends a signal to J7 12 which is optically coupled to the time delay module where it overrides the retransfer timer In response to this signal the time delay module signals K15 and retransfer occurs without delay For Normal operation the Test Normal Transfer switch must be in the Normal position ADJUSTING POWER SENTRY MODULES AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause serious personal injury
92. contacts Contact Assemblies The automatic transfer switch has three or four poles Three pole transfer switehes are vided with a neutral bar The contact assemblies make and break the current flow When closed to either the Normal or the Standby power source the contacts are mechanically held A mechanical in terlock prevents them from closing to both power sources at the same time Linear Actuator The linear actuator is a lin ar induction motor that moves the contact assemblies between the Normal power source and the Standby power source Nor mally linear actuatof operation is initiated electri cally Manual operation of the transfer switch is also possible 4 Manual Operation in this section Motor Disconnect Switch The Motor Disconnect toggle switch on the acces sory Control panel enables and disables the linear actuator Place the switch the Off position for Manualhoperation and in the Auto position for elec trical locaV remote operation Auxiliary Contacts Auxiliary contacts are provided on the Normal and Emergency Standby sides of the transfer switch They are actuated by operation of the transfer switch during transfer and retransfer The Normal side auxiliary contact switch is actuated when the transfer switch is in the Normal position The Emer gency side auxiliary contact switch is actuated when the transfer switch is in the Emergency posi tion Connections for t
93. correspond ing switch terminals Leads are marked with the terminal numbers S2 NO S7 NC S9 C etc for identification Refer to Figure 4 5 for identification of the auxiliary switch terminals Place the terminal bracket in position on the base and secure it with the hex head machine screws Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem Place the plastic switch cover in position and secure with machine screws 4 and flat wash ers 4 Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emer gency power source Place the operation se lector switch in the Remote position Test the switch for proper operation and close the cabinet SIDE WITH TWO TERMINALS SWITCH LEVER IN CLOSED POSITION NORMAL SIDE EMERGENCY SIDE INSULATING BARRIERS cac x SCREWS D ow G TORQUE TO 10 TO 15 IN LBS 1 1 TO 1 7 Nem SC1557s FIGURE 4 5 AUXILIARY SWITCHES 40 TO 125 AMPERES 4 8 LINEAR ACTUATOR REMOVAL AND REPLACEMENT 150 to 260 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If t
94. ct switch to the Off position 4 Transfer from the Normal to the Standby power source A Pull the upper manual operator handle down B Push the lower manual operator handle down Retransfer from the Emergency to the Nor mal power source C Pull the lower manual operator handle up D Push the upper manual operator handle up Transfer switch operation re sults in rapid movement of the manual op erator handles and presents a hazard of se vere personal Injury Keep hands clear of handles when switching back to Auto to electrical operation move the Mo tor Disconnect switch to the Auto position Close and lock the cabinet door If remote control operation is being used place the Local Remote switch the Remote posi tion TROUBLESHOOTING The following procedures describe preliminary troubleshooting checks AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death For this reason do nottouch or allow clothing tools or jewelry to contact ex posed electrical terminals whenever the cabi net door Is open Make sure you are standing on a dry Insulating surface Transfer Switch Does Not Transfer To The Standby Source 1 Check the Motor Disconnect switch It should be in the Auto position 2 the Loca Remote and Normal Standby switches in the correct positions 3 Has the programmed transition time delay
95. door by disconnecting connector J1 P1 on theaccessory control panel before removing and replacing components 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 Automatic transfer switch operation results in rapid movement of the Switch mechanism and presents a hazard of severe personal Injury Keep hands clear of the switch handles when switching to automatic operation TROUBLESHOOTING 3 1 Transfer Switch Does Not Retransfer When Normal Voltage Returns After A Power Outage This procedure Is to be performed with the generator set running and Normal voltage on line MAKE SURE THAT THE MOTOR DISCONNECT SWITCH IS IN THE AUTO POSITION NOTE If the Program Transition module Is used and transfer switch only moves to the mid transition disconnected position the trouble may be In Program Transition module or relay Place the Delay No Del y switch In the No Delay position If retransfer occurs replace the Program Transition module If retransfer does not occur replace K3 When taking voltage measurements be sure thatthe probe penetrates the con formal coating on the boards 1 15 the Retransfer Timing lamp on th time delay board lit Is the Retransfer Timing Complete lamp lit Is the Source Available lampon the Source 1 voltage sensor lit Refer to Source 1 voltage sensortroubleshoo
96. e severe personal Injury or death Disconnect all sources of AC power from the transfer swltch before servicing The following procedures cover the removal and replacement of the block and crossbar assemblies for 40 to 125 ampere switches Removing the Block and 55 Assembly Normal or Emergency 1 Remove the linear actuator as described Linear Actuator Removal and Replacement section for 40 to 125 ampere switches Fol low steps 1 6 in the Removing Actuator sec tion 2 Remove the round head machine screwsand flat washers that secure the interlock barto the interlock arms see Figure 4 3 and remove the interlock bar 3 Disconnect the control wiring leads from the jumper bus bars 4 Remove the hex head machine screws ring terminals flat washers lock washers and nuts that secure th jumpersbus bars see Figure 4 3 to the load bus bars 5 Remove the hex head machine screws and spring washersethat secure the jumper bus bars to the block assemblies and lift off the jumpefibus bars 6 Refnove the control wiring leads from the power source terminals Figure 4 4 7 Goosen the lug terminal screws and remove the power source supply wires from the lug ter minals 4 4 8 Remove the two round head machine screws lock washers and flat washers that secure the block assembly to the base and carefully move the assembly Use care when removing the block and cross bar assembly from t
97. e switch is allowed to transfer or retransfer There are three other relays with form C contacts on the Signal Module Source Available Source 2 Available Backup Source Available Theserelays are not affected by the Elevator Signal delay They respond directly to signals from the Power Sentry Timing 5 Seconds 60 Program Transition FIGURE 6 4 PROGRAM TRANSITION MODULE No igna E owe Signal Module e 16 J21 c Timing 4 5 2 Seconds 50 SC1584 FIGURE 6 5 SIGNAL MODULE The Source 1 and Source 2 Available relays ergized when their respective power sources are producing adequate power In utility to utility applications the Backup Source Available relay is energized whenever the desig nated backup source is producing adequate power All relay contact connections are made at TB3 Re fer to sheet 1 of your schematic and wiring diagram package To set the time delay align the slot on the potenti ometer with the desired marking on the faceplate Figure 6 5 time delay is desired make sure that the Delay No Delay switch is in the Delay position Auxiliary Relays Option Optional auxiliary relays provide contacts for ener gizing external alarms remote indicators and con trol equipment such as louver motors and water pumps Connections to the auxiliary relays are made di rectly to the relay terminals The ter
98. e stop minute Press the 1 7 button 5 to advance the indica tor bar 14 from 1 to 7 and back to 1 For each start time selected in step 5 above there must be a corresponding stop time A program can start on day 2 pass through midnight and stop on day 3 for example but there must be a stop time for every start time Press the Q button 7 when the indicator is under the de sired day number To enter the complete start stop program press the Pr button 8 If all program require ments have been satisfied the display returns tothe time of day If the program requirements are not met the display of the sectionathat needs correction flashes on and off To enter more programs repeat the two 5 step pro cedures A maximum of ten programs en tered The same ten programs can be repeated each day The word Full appears in the display When the memory is full Ifthe button 2 is pressed no program is to be entered press the Ch 6 and then the Pr button 8 to get out of the program mode To check the programs 1 Press the Ch b tton 6 4 12 and an 15 are displayed Press the Ch button 6 again The start and stop information for the first program is dis played Continued pressing of the Ch button 6 causes the display to sequence through all of th programs in memory If ten programs have been entered the word Full appears aft
99. el BATTERY NC VOLTAGE NO gggg LIII BATTERY NC VOLTAGE NO 21 COE LII 8 1578 2 FIGURE 5 11 10 AMP CHARGER ALARM CONTACTS Auxiliary Relays Option Optional auxiliary relays provide contacts for ener gizing external alarms remote indicators and con trol equipment such as louver motors and water pumps Connections to the auxiliary relays are made di rectly to the relay terminals The terminals accept wire sizes from one 18 AWG wire to two 12 AWG wires There are three types of auxiliary relay coils 12 VDC 24 VDC and 24 VAC Table 5 1 lists several auxiliary relay options All relays have two normally open and two normally closed contacts that are rated for 6 amperes at 600 SC1576 VAC Figure 5 12 The AC relays are energized by the same signals that power the corresponding indicator lamps on the cabinet door The Emergency and Normal DC relays are ener gized to indicate transfer switch position The Gen set Run DC relay is energized only when the 2 wire start signal is present at the RMT terminal of TB2 Refer to sheet 1 and to the drawings referenced on sheet 3 of your schematic and wiring diagram pack age s s 21 FIGURE 5 12 AUXILIARY RELAYS TABLE 5 1 AUXILIARY RELAY OPTIONS 24 24 VAC Coil 24 24 Coil 24 Coil 24 24 24 24 Coil 12
100. eme caution to avoid touching electrical contacts whenever the cabinet door 15 open If possible remove all AC power to the transfer switch before manually operating the switch It Is necessary to perform manual operation with AC power connected follow the Safety Related Work Practices listed In 1 Open the cabinet door of the automatic trans fer switch 2 Move the Motor Disconne t switch to the Off position 5 14 3 Transfer from the Normal source 1 to the Emergency source 2 power source A Pull the upper manual operator handle down B Push the lower manual operator handle down Retransfer from the Emergency Source 2 to the Normal source 1 power source C Pull the lower manual operator handle up D Push the upper handle up Before moving the Disconnect switch back to the Auto positioh remember the trans fer switch will4fansferload to the active power source If both power sources are available it will transfemtheload to the priority source Automatic transfer switch op eration results rapid movement of the manual operator handles and presents a hazard of severe personal Injury Keep hands clear of the handles when switching back to automatic operation 5 Move the Motor Disconnect switch to the Auto position 6 Close and lock the cabinet door Overcrank Reset 3 Wire Start Only An overcrank condition exists when the
101. emoval and Replacement 300 to 600 Amperes 4 17 Block and Crossbar Removal and Replacement 300 to 600 Amperes 4 20 Auxiliary Switch Removal and Replacement 300 to 600 Amperes 4 23 Linear Actuator Removal and Replacement 800 and 1000 Amperes 4 25 Block and Crossbar Removal and Replacement 800 and 1000 Amperes 4 28 Auxiliary Switch Removal and Replacement 800 and 1000 Amperes 4 32 SECTION 5 7 of Contents continued TITLE PAGE GENSET TO GENSET 5 1 Intr dUcllon 4 s os ure Said ar eae aa Rage eae Re 5 1 Cabinet wc sid cok ws Soe ou ge Rees 5 2 Transfer Switch 5 3 Electronic Control System 9 5 3 cO D 5 14 Troubleshooting etc EDT 5 15 UTILITY TO UTILITY 6 1 Introduction N 6 1 Cabinet Qa rura asa EO ulula 6 2 Transfer Switch ola ri tpe eene 6 3 Electronic Control System R Fee nenne 6 3 Operation mE A 6 8 Troubleshooting 6 8 NONAUTOMATIC REMOTE 22 gt
102. emove the control wiring leads from the power source terminals Loosen the lug terminal screws and remove the power source supply wires from the lug ter minals screwdriver dig the glue out of the insu lator cups that cover and insulate the block as sembly mounting screws 4 28 10 Remove the hex head capscrews and flat washers that secure the block assemblies Figures 4 18 and 4 19 to the base lift off the block assemblies note where spacers are used e On 3 pole switches the A phase block on the Normal side and the C phase block on the Emergency side have a spacer under thelr_otiter mounting tabs On 4 pole switches the A phase block on the Normal side and the neu tral block on the Emergency side have this spacer that you In stall new block assemblies with the spacers Jn thelr original positions The block assemblies are not identical The A ahd C phase blocks and the neutral block on 4 pole switches are different than the B phase block Refer to the parts manual and the part num bers stamped on the replacement block assemblies to make certain that you Install new block assemblies in their correct positions Remove the round head machine screws lock washers and flat washers that secure the arc chutes Figures 4 18 and 4 19 to the block as semblies and lift out the arc chutes arc chute barriers and arc chute spacers Discard the arc chute barriers
103. enerator set has priority Programming the Change over Clock The change over clock initiates generator set changeover at programmable intervals t is a 7 day 24 hour clock that can store and execute up to ten changeovers a week Programming the change over clock requires set ting the time of day and selecting the change over times The change over clock must be programmed to close its normally open contacts hold the con tacts closed long enough to allow the generator set to start and then open the contacts Refer to the circled numbers in Figure 5 4 when reading the following instructions To set the time of day 1 If 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 press the button if you are only changing the time of day 2 Press the clock button 1 3 Press the h button 3 to set the hour of the day The clock uses 24 hourmilitary time 4 Press the m button 4 to setthe minutes of the hour 5 Press the 1 7 button 5 to advance the indica tor bar over the desired day number Use the 1 to represent 6 Press the Pr button 8 to enter the time To set the change over time 1 Slide the output selector switch 16 to the cen ter The output selector switch has thre positions The Off position overrides the program and holds the contacts open The positiorr overrides the program and hold
104. ensing are available as a single option Overvoltage Sensing With optional overvoltage sensing the Normal and Emergency sources are monitored for an overvoltage condition As with the standard ndervoltage sensing the voltage sensors signal the time delay module which controls the transfenor retransfer sequence An adjustable time delay 0 to 120 seconds over rides momentary evershoots in voltage To set this time delay align the slot on the potenti ometer withithe desired marking on the Power Sen try cover Overvoltage adjustment and calibration proce dures are described in section 2 Frequency Sensing With optional frequency sensing the Normal and Emergency sources are monitored for variations in frequency The sensors determine whether the source is within an adjust able bandwidth As with the standard undervoltage sensing the fre quency sensors signal the time delay module which controls the transfer or retransfer sequence An adjustable time delay 0 to 15 seconds allows the control to ignore momentary dips or rises in fre quency To set this time delay align the slot on the potenti ometer with the desired marking on the Power Sen try cover Programmed Transition Option The optional Program Transition module Figure 6 4 is used to introduce a pause during transition Programmed transition allows the transfer switch to assume a mid transition position for an adjustable interval of time whe
105. equency return Af ter the delay the transfer switch can retransfer the load to the Normal source allows the Normal source to stabilize before retransfer It has an adjustable range of 0 to 30 minutes OPTIONAL OPTIONAL SIGNAL PROGRAMMED MODULE TRANSITION INDICATOR LAMPS OPTIONAL METERS OPTIONAL 3 WIRE START OPTIONAL EXERCISER CLOCK SWITCHES ACCESSORY DISCONNECT PANEL SWITCH TEST amp EXERCISE POWER WITH WITHOUT SENTRY LOAD SWITCHES CONTROL AUTOMATIC BATTERY TRANSFER CHARGER SWITCH SC1581 FIGURE 1 3 UTILITY TO GENERATOR SET TRANSFER SWITCH INTERIOR COMPONENTS Undervoltage Sensing Two voltage sensors one for the Normal side and one for the Emergency side monitor source volt ages for an undervoltage condition and generate signals which are sent to the time delay module If for example an undervoltage condition is sensed on the Normal source the voltage sensor module sends a signal to the time delay module that initi ates and controls the timing for generator set start and the transfer of load The standard transfer switch has undervoltage sensing for all phases of the Normal and Emer gency power sources Overvoltage and Frequency Sensing Option Overvoltage and frequency sensing are available as a single option Overvoltage Sensing With optional overvoltage sensing the Normal and Emergency sources are monitored for an overvoltage condition
106. er source the contacts are mechanically held A mechanical interlock prevents t em from closing to both power sources at the same time Linear Actuator The linear actuator is a linear induction motor that moves the contact assemblies between the Normal source 1 power source and the Emergency source 2 power source Linear actuator operation is initiated automatically with automatic transfer Switches Manual operation ofthe transfer switch is also possible Referto Manual Operation in the Op eration section 6 3 Motor Disconnect Switch The Motor Disconnect toggle switch on the acces sory control panel enables and disables the linear actuator Place the switch in the Auto position to enable the linear actuator Place the switch in the Off position to disable the linear actuator Auxiliary Contacts Auxiliary contacts are provided on the Normal and source 1 and Emergency source 2 sides of the transfer switch They are actuated by operation of the transfer switcheduring transfer and retransfer The Normal side auxiliary contact switch is actu ated when the transfer switch is in the Normal posi tion The Emergency side auxiliary contact switch is actuated when the transfer switch is in the Emer gency po ition The auxiliary contacts have current ratings of10 amperes at 250 VAC Connections for the auxiliary contacts are made on terminal block 1 Refer to sheet 1 of your schematic and wiring diagram package ELECT
107. er switch discussed here are the contact assemblies linear actuator capacitor s Motor Disconnect switch auxiliary switches and auxiliary contacts Transfer switch assembly maintenance procedures are described in Section 4 Contact Assemblies The transfer switch either has three or four poles Three pole transfer switches are provided with a neutral bar The contact assemblies make and break the current flow When closed to either the Normal or the Emergency power source the con tacts are mechanically held A mechanical inter lock prevents them from closing to both power sources at the same time Linear Actuator The linear actuator is a linear induction motor that moves the contact assemblies between the Normal power source and the Emergency power source Linear actuator operation is initiated automatically with automatic transfer switches Manual operation of the transfer switch is also possible Refer to Manual Operation Capacitor s Either one ortwo capacitors referto Section 4 pro vide the phase shift necessary to drive the linear motor If the capacitor is faulty the linear motor does not operate Motor Disconnect Switch The Motor Disconnect toggle Switch on the acces sory control panely enables and disables the linear actuator circuit Place switch in the Auto posi tion to enable the linearactuator Place the switch in the Off position to disable the linear actuator Auxiliary Switches Eight auxi
108. er the tenth program display Press the Pr button 8 to return to the time of day display 2 26 To change edit a program 1 Press the Ch button 6 until the program you want to change appears in the display window 2 Press the I O button 2 to select start or stop time 3 Press the h 3 m 4 or 1 7 5 and 7 but tons to change the hour minute or day 4 Press the Pr button 8 to enterthe edited pro gram and return to display To erase clear a program 1 Press the Ch until the program to be erased is displayed 2 Press the G button 10 with a ball point pen to clear the program 3 Press the Pr button 8 to return to the time of day display Battery Charger Float Voltage The float voltage is set at the correct value at the factory and should not require adjustment How ever if the battery shows signs of being over charged or undercharged the float voltage can be adjusted A high specific gravity bubbling of elec trolyte and loss of water indicate a high float volt age Alow specific gravity indicates a low float volt age Ignition of explosive battery gases can cause severe personal Injury not smoke or cause any spark arc or flame while servicing batteries To change the float voltage a fully charged battery a hydrometer a small screwdriver and an accurate voltmeter 0 5 accuracy are needed Use the fol lowing
109. ers spring washers ring terminals and nuts Figure 4 13 and 4 14 Be sure to apply a thin coat of electrical joint cCompound between the current carrying surfaces Tighten 70 to 75 in Ibs 7 9 10 8 5 Install the actuator handle on the block assem bly with the shoulder screws and lock washers Tighten to 25 030 in Ibs 2 8 to 3 4 Nem Ap ply a thin coat of lubricant Onan part number 524 0157 to the slot in the handle Connect the power source supply wires to the lug terminals Tighten the lug terminals to the 4 23 torque value silkscreened on the transfer switch cover Connect the control wiring leads to the p wer source terminals Control wires marked NORM A B C or EMER for identification Connect the control wiring leads to the jumper bus bars Control wires are marked LOAD for identification Apply thread Loctite 242 Onan part number 518 0309 is recommended to the threads of the interlock bar capscrews Install the interlock bar and secure to each interlock arm with a hex head capscrew lock washer and flat washes Tighten to 70 to 75 in Ibs 7 9 to 8 5 Attempt to close both sides of the transfer switch The interlock assembly must hold one Side open so that only one side closes at at time Replace the linear actuator as described in the Linear Actuator Removal and Replacement section for 300 to 600 ampere switches Fol low steps 2 t
110. ers that secure the rod end assembly to the end of the actuator rod 9 Remove the rod end assembly from the actua tor rod Figure 4 6 and slide the rod out of the actuator motor Replacing Actuator 1 Insert the actuatorfod into the replacement ac tuator motor Figure 4 7 Hold the actuator ground brush up slightly to allow passage of the actuator rod Install the rod end assembly and tighten the capscrew to 70 to 75 in Ibs 7 9 to 8 5 Nem 2 actuator motor in position over the switch assemblies so the lead wires are at the bottom and fit the rod assembly into the han dle of the closed switch assembly the actuator motor to the switch as semblies using hex head capscrews 4 lock washers 4 flat washers 4 barriers 2 and spacers 4 Tighten the capscrews to 45 to 50 in Ibs 5 1 to 5 7 Nem 4 Connectthe black actuator lead wire to the cir cuit breaker and the red and white actuator lead wires to the following capacitor terminals RedLead Wire Connectto capacitor C1 Ter minal 1 White Lead Wire If one capacitor connect to capacitor C1 Terminal 2 If two capacitors connect to capacitor C2 Terminal 2 Transfer switches for voltage ranges 347 380 416 and 440 480 use two capacitors C1 and C2 wired together In series A single jumper wire Is placed between terminal 2 on C1 and terminal 1 on C2 5 Replace the capacitor end cap s and install the capacitor s in
111. et to the neutral block Fig ure 4 14 Remove the block and cross bar as sembly Save the bearing bracket and screw for reuse Use care when removing the block and cross bar assembly from the base Carefully disengage the crossbar from the auxiliary switch assembly to avoid cracking the switches 10 On 4 pole switches Figure 4 14 Remove the four screws that secure the block and con tact assembly to the base and lift off the block and contact assembly Remove the hex head capscrew and lock washer that secure the interlock arm assembly to the block assembly and lift off the interlock arm 11 INTERLOCK ARM CIE LOAD BUS BAR BUS BAR 1 TORQUE TO 70 TO 75 IN LBS 7 9 TO 8 5 Nem 2 TORQUE TO 10 TO 12 FT LBS 13 6 TO 16 3 Nem 3 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem FIGURE 4 13 3 POLE SWITCH ASSEMBLY 300 TO 600 AMPERES 4 21 INTERLOCK INTERLOCK 2 3 3 INTERLOCK ARM BAR ARM b A o o s PT O O gt V 9 FERIIS KC ey sl Vg 554 sad mr 534 uj 524 juri D qm 3 Q Q JUMPER BUS BAR 3 JUMPER LOAD BUS BUS BAR BAR TO 70 TO 75 IN LBS 7 9 TO 8 5 Nem TO 10 TO 12 FT LBS 13 6 TO 16 3 Nem S TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem FIGURE 4 14 4 POLE SWITCH ASSEMBLY 300 TO 600 AMPERES 4 22 9 NEUTRAL BLOCK AND
112. ete a transfer to the other source This module is available with two adjustment ranges 0 to 7 5 seconds or 0 to 60 seconds To set the time delay align the slot on the potenti ometer with the desired marking on the faceplate If a time delay is desired make sure that the Delay No Delay switch is in the Delay position Signal Module The Signal Module has one adjustable timer The Elevator Signal delay controls the timing of two events It delays transfer retransfer and energizes the Elevator Transfer Signal relay during the delay period This time delay is adjustable over a range of 0 to 50 seconds To set the time delay align the slot on the potenti ometer with the desired marking on the faceplate If atime delay is desired make sure that the Delay No Delay switch is in the Delay position Exerciser Clock The exerciser clock initiates generator set start run cycles at programmable intervals and for program mable 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 setting the time of day and entering the exercise start and stop times Refer to the circled numbers in Figure 2 15 when reading the following instructions To set the tlme of day 1 If you are performing installation and setup pressthe R button 9 withthe tip of a ball point pen to reset all memory Do not press the R button if you are only ch
113. fer switch to Test The generator set should start and as sume the load after the transfer time delay At the end of the test period move the Test Normal Retransfer switch to the Normal posi tion if you want to retransfer load back to the Normal power source after the retransfer time delay Tobypass the retransfer time delay and cause immediate load retransfer move the Test Normal Retransfer switch to Retransfer and release the switch will return to Normal The generator will stop after the stop time de lay In anticipation of scheduled or automatic gen erator set exercise check that the With With out Load selector switches are in the desired positions Refer to Generator Set Exercise 6 Close and lock the cabinet door Overcrank Reset An overcrank condition exists when the generator set fails to start within the time limit When this con dition occurs the Lockout lamp on the 3 Wire Start module will light To restore the automatic starting circuit 1 Correct the engine starting problem 2 Push the Overcrank Reset button and release 2 PREVENTIVE MAINTENANCE Performing the yearly preventive maintenance procedures in Table 1 1 will result in operational reliability of the transfer switch AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death In addition incorrect Installation service or parts replacement can result In severe
114. figurations Use normal and necessary safety precautions be fore starting any service procedures Identify hazards by referring to the Safety Precautions printed inside the front cover and observe all warn ings and cautions within the manual Whenever troubleshooting remember that generator set transfer switch and utility power source are all in terdependent TRANSFER SWITCH ARPLICATION Transfer switches are essential part of a build standby or emergency power system The Normal power source commonly the utility line is backed up by an Emergericy power source often a generator The transfer switch supplies the electrical load with power from one of these two power sources The load is connected to the common of the trans fer switch Figure 1 1 Under normal conditions the lo d is supplied with power from the Normal source as illustrated If the Normal power source is interrupted the load is transferred to the Emer gency power source When Normal power returns the load is retransferred to the Normal power Source The transfer and retransfer of the load are the two most basic functions of a transfer switch Power Sentry is a registered trademark of Onan Corporation NORMAL LOAD 4 FIGURE 1 1 LOAD TRANSFER SWITCH TYPICAL FUNCTION AUTOMATIC TRANSFER SWITCHES Automatic transfer switches capable of automatic operation without operator invol
115. fter the delay the transfer switch transfers the load to the generator set This brief time delay allows the generator set to stabiliZe be fore the load is applied It has an adjustable range of 0 to 120 seconds To set this time delay align the slot on the potenti ometer with the desired marking on the try cover Retransfer Time Delay This delay begins the mo ment the preferred source voltage and frequency return After the delay the transfer switch can retransfer the load to the preferred source The de lay allows the preferred stabilize before retransfer It has an adjustable range of to 30 minutes To set this time delay align the slot on the potenti ometer with thedesired marking on the Power Sen try cover Undervoltage Sensing Two voltage sensors one for the source 1 side and one forthe source 2 side monitor source voltages for an_undervoltage condition and generate sig nals which are sent to the time delay modulemlf for example an undervoltage condition is sensed on the priority source the voltage sensor module sends a signal to the time delay module that initi ates and controls the timing for generator set start and the transfer of load The standard transfer switch has ndervoltage sensing for all phases of the Source 1 and source 2 power sources Undervoltage adjustment and calibration proce dures are described in section 2 Overvoltage and Frequency Sen
116. g connector J1 P1 on the accessory control panel before removing and replacing components 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 Ignition of explosive battery gases can cause severe personal Injury of death Do smoke or cause any spark or flame while servicing batteries TROUBLESHOOTING 3 5 Generator Does not Crank for a Power Failure Test or Exercise Using a Two Wire Starting System This procedure Is to be performed with the Normal voltage available and the Test Nor mal Retransfer switch the Test position When taking voltage measurements be sure that the probe penetrates the conformal coating on the boards Does the generator set crank using the generator set Start switch Check the battery voltage If the battery is low themeharge it or replace it If battery is OK then there is a problem with the generator set Consult the gen erator set manual Check the wiring from the battery to the transfer switch 15 there a jumper or closed circuit between TB2 B and TB2 2 There should be a jumper between TB2 GND and TB2 2 Install a jumper between 2 and TB2 2 If the generator set does not crank then go to Step 6 Is there 12 or 24 VDC between TB2 RMT and ground Are the wires from the generator set starting circuit to 2 and TB2 RMT connected pro
117. g transition Programmed transition is the capability of the trans fer switch to assume a mid transition position for an adjustable interval of time when the load is nei ther connected to the Normal power source nor to the Standby power source This feature allows residual voltage from motor loads to decay to an acceptable level before trans fer is completed The length of time thatthe transfer switch is in the midposition can be adjusted from to 7 5 seconds or to 60 seconds depending on the timer option The proper adjustment is a func tion of the motor and its connected load To set the time delay align the slot on the potenti ometer with the desired marking on the faceplate If a time delay is desired make sure that the Delay No Delay switch is in the Delay position Refer to sheets 2 and 5 of your schematic and wir ing diagram package Alarm Module Option The optional alarm module Figure 7 7 provides an audible indication that the transfer switch has trans ferred to the Standby power source A push button on the alarm module provides means to sllence the horn The Alarm lamp indicates that the transfer switch is in the Standby Connected position Ifthehomis si lenced the Hom Silenced lamp light Both lamps will stay lit until the transfer switeh moves from the Standby Connected position to the discon nected neutral or Normal Connected position 7 6 Timing Delay Seconds
118. generator set fails to start within the overcrank time limit When this condition occurs the Lockout lamp on the 3 Wire Start module will light To restore the automatic starting circuit 1 Correct the engine starting problem 2 Push the Overcrank Reset button inward and release to reset the overcrank relay TROUBLESHOOTING The following procedures describe preliminary troubleshooting checks Priority Generator Set Fails But Backup Generator Set Does Not Start 1 Two wire starting only Check the generator set The operation selector switch on the gen erator set control panel should be in the Re mote position Check for fault indicators on the generator set control AC power within the cabinet and the rear side of the cabinet door pre sents a shock hazard that can cause severe personal Injury or death For this reason do not touch or allow clothing tools or jew elry to contact exposed electrical terminals whenever the cabinet door Is open Make sure you are standing on a dry Insulating surface 2 Three wire starting only The Auto Stop Handcrank switch on the 3 Wire Start mod les should be in the Auto position Check fof over crank condition See Operation Section 3 Start the generator set using its start stop trols The Auto Stop Handcrank switch on the 3 Wire Start module must be in the Handerank position If it does not crank check the start ing battery If it cranks butedoes not start c
119. h will transfer load to the active power source if both power sources are available it will transfer the load to the Normal source Automatic transfer switch op eration results rapid movement of the manual operator handles and presents a hazard of severe personal Injury Keep hands clear of handles when switching back to automatic operation Move the Motor Disconnect switch to the Auto position 6 Close the cabinet door 5 Generator Set Exercise Run the generator set for at least 30 minutes once each week with at least 50 percent load if possi ble If you do not have an optional exerciser use the Test Normal Retransfer switch to test the gen erator set each week The optional exerciser has preselected exercise periods and exercises the generator set automati cally with or without load depending on the position of the Exercise With Without Load switch If the Normal power source has an interruption while the generator set is exercising without load the auto matic transfer switch will transfer the load to the generator set Generator Set Start Test AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death Use extreme caution to avoid touching electrical contacts whenever the cabinet door Is open 1 Place the Test With Without Load selector switch on the Power Sentry control in the Without Load position The Test With Without L
120. han 300 VAC transformer T3 is used be tween 513 and the meters to step down the volt age Power to the ammeter is supplied from current transformers through switch S 13 and directly to the ammeter Cables fromthe source are passed once through the current transformers Refer to sheets 2 and 5 of your schematic and wir ing diagram package Auto Manual Switch The optional Auto Manual switch is used to enable or disable the automatic retransfer function This switch has two positions In the Auto mal automatic retransfer is enabled Manual position automatic retransfer iszdisabled only manually initiated retransfer is possible In the Manual position the switch closes and pro vides a ground at J7 3 on the Power Sentry mother board This signal is optically coupled to the time delay module where it overrides the automatic retransfer timer Refer to the Power Sentry mother board schematic Section 8 and to sheet 3 of your schematic and wiring diagram package 600 VAC Adapter Transformer On 600 switches transformer T4 is connected between phase and B Sources and the linear ac tuator to step down the AC voltage A special pair of interposing relays 1 and K2 equipped with a mechanical interlock allow only one source Nor mal or Emergency to be connected to the trans former at a time Referto sheets 2 and 4 of your schematics and wir ing diagram package Alarm
121. he base Carefully disengag the cross bar from the auxiliary switch lever to avoid cracking the switch lever Replacing the Block and Cross Bar Assembly 1 Clean all current earrying surfaces with a wire brush 2 Hold the block assembly in position on the check the alignment of the auxiliary switch lever When the main switch contacts the auxiliary switch lever must aligned vertically as shown in Figure 4 3 Move the auxiliary switch lever as required to get correct alignment 3 Secure the block assembly to the base with round head machine screws 2 lock washers 2 and flat washers 2 Tighten the screws to 25 to 30 in Ibs 2 8 to 3 4 Nem 4 Install the power source supply wires and se curely tighten the lug terminals 5 Connect the control wiring leads to the corre sponding power source terminals Control wires are marked NORM A B C or EMER A B C for identification 6 Apply athin coat of electric joint compound be tween the mating surfaces of the jumper bus bars braided strap connector and load bus bars 7 Install the jumper bus bars and secure to the switch assemblies with hex head machine screws and spring washers Tighten to 2510 30 in Ibs 2 8 to 3 4 Nem torque 8 Secure the jumper bus bars to each load bus bar using a hex head machine screw ring ter minal flat washer lock washer and nut Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque 9
122. he Power Sentry control Figure 2 1 consists of the following major components Transformer assembly Mother board Voltage sensor modules e e e e Time delay module All components of the Power Sentry control are mounted within a single enclosure The timing sensitivity and calibration potentiome ters and LED control lampsare visible and accessi ble through holes on the controlCover Figure 2 1 The following text provides description of each component and how it functions Transformer Assembly The transformer assembly is mounted in the control as shown in Figure 2 1 The assembly includes four transformers a terminal block and a ribbon cable connector The transformers step down the line voltage to approximately 18 VAC The output from the transformers is supplied to the mother board rectifier bridges The transformer assemblies are not the same for every control even though they may appear identi 2 1 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 rea son the transformer assemblies from different con trols are not necessarily interchangeable When replacing a transformer assembly note that the transformer input leads are wired with a line to line or line to neutral eonfiguration and with jumper wires across the TB11 terminals The wir ing and jumpef wire configurations are vo
123. he auxiliary contacts are made on terminal block TB1 The contacts have ratings of 10 amperes at 250 VAC Referto sheet 1 of your schematic and wiring diagram package OPTIONAL PROGRAMMED TRANSITION INDICATOR LAMPS OPTIONAL METERS SWITCHES ACCESSORY MOTOR reci CONTROL DISCONNECT ASSEMBLY PANEL SWITCH SC1581 1s FIGURE 7 3 NONAUTOMATIC REMOTE CABINET INTERIOR 7 4 OPTIONAL CONTROL COMPONENTS Remote Control Circuit Connections Remote control circuit connections are made atter minals 1 2 and 3 of TB2 Figure 7 4 Closing the contacts across terminals 1 and 2 causes transfer to the Normal source Closing the contacts across terminals 1 and 3 causes transfer to the Standby Source Terminal 4 of TB2 Is not used Terminals 5 and 6 of TB2 are used for the transfer Inhibit Input with paral leling systems only For normal operation there is a jumper across terminals 5 and 6 Load Shed The Load Shed function is used to disconnect the load from an available Standby source in order to reduce the power consumed from that source When the load shed function is initiated the trans fer switch is moved to the neutral position Theload shed function is initiated by closing a set of normally open contacts across terminals 7 and 8 of TB2 If the load shed signal is removed the switch will transfer back to the Standby source if the Standby source is available When load shedding
124. he source 1 generator set control TB3 terminals 6 unit 2 and 36 37 and 38 unit 1 are for connection to the overcrank alarm contacts See Figure 5 7 These form C contacts are rated for 4 5 at 125 or 3 amperes at 30 VDC and are pr vided for customer use terminals 7 9 and 10 unit 2 and 37 39 and 40 unit 1 are for connection to the generator run ning contacts Terminals 7 and 37 are common to both overerank alarm and generator running relay contatts See Figure 5 7 These form C contacts are tated for 4 amperes at 125 VAC or 3 amperes at 30 VDC and are provided for customer use Refer to sheet 1 of the schematic and wiring diagram package that was shipped with the transfer switch SOURCE 2 GENERATOR SET TERMINALS GROUND OVERCRANK ALARM CONTACTS GENERATOR RUNNING CONTACTS SOURCE 1 GENERATOR SET TERMINALS 52 OVERCRANK ALARM rcha e 5 nobel ef e mE RUNNING 5 4 FIGURE 5 7 THREE WIRE START CONNECTIONS Programmed Transition Option The optional Program Transition module Figure 5 8 is used to introduce a pause during transition Programmed transition allows the transfer switch to assume a mid transition position for an adjustable interval of time In this position the load is not con nected to either power source This feature allows residual volt
125. heck the fuel supply AWARNING Ignition of explosive battery gases can cause s vere personal Injury Do not smoke or spark or flame while servicing batterles Ignition of fuel can cause se vere personal Injury or death by fire or plosion Do not permit any flame cigarette spark pllot light arcing equipment or other possible source of ignition near the fuel system Set Starts When Not Scheduled 1 Two wire starting only The operation selec tor switch on the generator set control panel should be in the Remote position 3 4 AC power within the cabinet and the rear side of the cabinet door pre sents a shock hazard that can cause personal Injury or death For this reason do not touch or allow clothing tools or jew elry to contact exposed electrical terminals whenever the cabinet door 15 open Make sure you standing son a dry Insulating surface Three wire starting only The Auto Stop Handcrank switch on the 3 wire start module should be in the Auto position Check the source selector switch on the cabi net door to 5 it is in the Auto position Check the change over clock to verify the change over schedule The procedure for checking the change over program is de scribed under Programming the Change over Clock If change over is Incorrectly programmed re fer to the change over clock programming pro cedure
126. here is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal injury or death Disconnect 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 to 260 ampere switches Removing Actuator 1 Open the transfer switch cabinet door 2 Loosen and remove the two self locking nuts and the two machine screws with flat wash ers that secure the plastic switch covert the switch base and lift off the cover Figure 4 6 Separate the actuator lead wires from the rest of the wiring harness remove wire ties as re quired 4 Pry capacitor s loosesfrom the bracket Remove the end cap and disconnect the red and white actuator lead wires from the capaci tor terminals 5 Disconnect the black actuator wire from the cir cuit breaker and disconnect the ground wire from end of th actuator 6 hex head capscrews flat wash ers and lock washers that secure the actuator to the switch a semblies Figure 4 6 and lift out the spacers 4 and barriers 2 4 9 7 Disengage the actuator rod from thesswitch handle and remove the actuator from the switch assembly 8 Remove one of the hex head capscrews and lock wash
127. his allows the source 1 sensor to sense Normal power begin retransfer timing 2 20 Meanwhile the closure of K13 2 K13 3 contacts does not energize K11 because contacts K16 2 K16 4 are open and because therevis no stop signal being sent from the time delay module J2 13 K16 stays energized and its open as long as the transfer switch is in the Emer gency position After the retransfer delay has timed out the time delay module signals 1 5 to the Normal power source occurs retransfer K16 is de energized and contacts K16 2 K16 4 close The closure of these contacts completes the circuit to K11 After the Stop time delay times out the time delay sends out a stop signal J2 13 that passes through contacts K13 2 K13 3 and K16 2 K16 4 This signal terminates both two wire and threeswire Start signals Instant Retransfer When testing with load you can 55 delay by moving the Test Normal Retransfer switch to the Retransfer position This sends a signal to J7 12 which is opti cally coupled to the time delay module where it ov rrides the retransfer timer In response to this signal the time delay module signals K15 and retransfer occurs without delay For Normal operation the Test Normal Transfer switch must be in the Normal position Test Exercise With Without Load Mother Board 300 3953 Tofollow this descr
128. hock hazard that can cause severe personal Injury or death Use extreme avoid touching electrical contacts whenever the cabinet door 15 open The high and low alarm adjustments are set at the factory The ranges and factory settings are 12 volt charger 9 4 18 VDC LO Alarm Factory Setting 12 5 VDC 14 VDG40 19 VDC HI Alarm Factory Setting 14 5 VDC 24 volt charger 18 VDC to 25 VDC LO Alarm Factory Setting 25 VDC 27 VDC to 36 HI Alarm Factory Setting 29 VDC AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death Use extreme cautlon when making ad justments to avold touching electrical contacts 1 Open the cabinet door 2 Use a small screwdriver to turn the HI Alm or LO Alm adjustment potentiometers on the charger panel counterclockwise to decrease the alarm voltage and clockwise to increase the alarm voltage The graduations on the ad justment potentiometers are approximate 1 volt When finished close and lock the cabinet door When you have finished the adjustments of the optional control modules place the Motor Dis connect Switch on the accessory control panel in the Auto position and close and lock the cabinet door Automatic transfer switch opera results rapid movement of the manual operator handles and presents a hazard of severe personal Injury Keep hands clear of
129. hrough 9 in the Replacing Actuator section Test the switch for proper operation and close the cabinet AUXILIARY SWITCH REMOVAL AND REPLACEMENT 300 TO 600 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal Injury or death Disconnect all sources of AC power from the transfer switch before servicing 10 11 12 13 14 The following procedures cover the removal and replacement of the auxiliary switch assembly for 300 to 600 ampere switches AC power within the cablnet pre sents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing Removing Auxiliary Switch Assembly 1 After disconnecting all sources of AC power open the transfer switch cabinet door Loosen and remove the four machine screws that secure the plastic switch cover to the transfer switch and lift off the cover Loosen and remove the four machine screws that secure the terminal bracket Figure
130. iming period the lamp goes out and the Transfer Complete lamp turns on Transfer Timing Control is signaling forretransfer to Source 2 power The Source 2 Available lamp is also on Transfer Complete ACCESSORY CONTROL PANEL AND TERMINAL BLOCKS The accessory control panel Figure 2 2 includes e T1 and T2 transformers T3 optional transformer K1 and K2 interposing relays and K4 optional relays Motor Disconnect Switch S1 Connectors J1 J2 and J3 e TB4 terminal block Not included on the accessory control panel but re lated in function are terminal blocks TB1 TB2 and TB3 Figure 2 3 Transformers Transformers T1 and T2 provide 24 VAC power for the cabinet door display lamps relays K1 K2 and K16 and the optional exerciser clock K16 is on the mother board Refer to sheets 2 3 and 4 in your schematic and wiring diagram package Transformer T3 is used with the optional voltage and frequency meters on units that are rated at more than 300 volts Referto sheets 2 and 5in your schematic and wiring diagram package H2 H1 Relays Interposing relays and K2 are used to transfer line power to the linear actuator motor M1 The closing of K1 contacts causes retransfento the Nor mal side The closing of K2 contacts causes trans fer to the Emergency side K1 is energized by the closing of K15 contacts K2 is energized by the closing of K14 contacts 15 14 are on the mo
131. ion 2 Place the Motor Disconnect switch on the Ac cessory Control Panel in the Auto position 3 Close and lock the cabinet door Remotely controlled transfer to the Standby source is accomplished by closing a set of normally open contaets that are connected across terminals 1 and 3 of TB2 The contacts must be held closed until transfer is complete Remotely controlled retransfer to the Normal Source is accomplished by closing a set of normally 7 7 open contacts that are connected across terminals 1 and 2 of TB2 The contacts must be held closed until transfer is complete As with local operation the transfer switch permits transfer and retransfer only when 4he selected source voltage is present Manual Operation The transfer switch has perator handles for manu ally transferring the load Use the following proce dure AC power within the cabInetand the rear side of cabinet door presents a shock hazard that Can cause severe personal Injury or death Use extreme caution to avoid touching electrical contacts whenever the cabinet door 15 open If possible remove all AC power to the transfer switch before manually operating the switch If itis necessary to perform manual operation with AC power connected follow the Safety Related Work Practices listed In 70 1 Place the Local Remote switch in the Local po sition 2 Open the cabinet door of the transfer switch 3 Move the Motor Disconne
132. iption of Power Sentry control of generator set test and exercise functions refer to the schematic of mother board 300 3953 in sec tion 8 On the schematic locate switches S1 and S4 and relays K10 K11 K12 K13 K16 and K18 Locate the Test Normal Retransfer switch S12 on sheet 2 ofthe schematic and wiring diagram pack age Signal to Test Exercise The signals that initiate test or exercise enter the mother board at Local Test input J7 9 from the Test Normal Retransfer switch 512 3 512 4 e Exerciser Clock input J7 8 or e Remote Test input J8 7 These signals consist of a switch closing to ground The Exerciser Clock and Local Test inputs each have a corresponding With Without Load switch labeled S1 and S4 respectively If a switch is in the With Load position a local test or exercise signal will energize K18 If a switch is in the Without Load position a local test or exercise signal will energize K13 The Remote Testinput has no corresponding With Without Load switch This input is connected di rectly to relay K18 Without Load Test If the appropriate With With out Load switch S1 or S4 is in the Without Load position a local test or exercise signal will energize K13 When K13 is energized its normally closed contacts open When contacts K13 2 K13 4 open K11 the normally energized two wire start relay is de energized When K11 is de energized a start signal is sent to the generator set If applic
133. irements met the display of the section that needS correction flashes on and off To enter more programs repeat the ten step procedure A maximumof ten programs can be entered 5 7 The word Full appears in the display when the memory is full If the I O button 2 is pressed and program is to be entered press the Ch button 6 and then the Pr button 8 to get out of the program mode To check the programs 1 Press the Ch button 6 12 and an 15 are displayed 2 Press the Ch butt n 6 again The contact closing and contactopening information for the first program is displayed 3 Continued pressing of the Ch button 6 causes the display to sequence through all of programs in memory If ten programs have been entered the word Full appears after the tenth program display 4 Press the Pr button 8 to return to the time of day display edit a program 1 Press the Ch button 6 until the program you wantto change appears in the display window 2 Press the I O button 2 to select contact clos ing or contact opening time 3 Press the h 3 m 4 or 1 7 5 and Q 7 but tons to change the hour minute or day 4 Press the Pr button 8 to enter the edited pro gram and return to the time of day display clear a program 1 Press the Ch button 6 until the program to be erased is displayed 2 Pressthe C button 10
134. is delay prevents nui sance transfers to the backup power source caused by brief line fluctuations After the delay the transfer switch transfers the load to the backup power source It has an adjustable range of O to 120 seconds To set this time delay align the slot on the potenti ometer with the desired marking on the Power Sen try cover Retransfer Time Delay This delay begins when the preferred source voltage and frequency return After the delay the transfer switch can retransfer the load to the preferred source The delay allows the preferred source to stabilize before retransfer It has an adjustable range of O to 30 minutes To set this time delay align the slot on the potenti ometer with the desired marking on the Power Sen try cover Undervoltage Sensing Two voltage sensors one for the Normal side and one for the Emergency side monitor source volt ages for an undervoltage condition and gen rate signals which are sent to the time delay module Af for example an undervoltage condition is sensed on the Normal source the voltage sensor module sends a signal to the time delay module that initi ates and controls the transfer of load The standard transfer switch undervoltage sensing for all phases of the Normal and Emer gency power sources Undervoltage adjustment and calibration proce dures are described in section 2 6 5 Overvoltage and Frequency Sensing Option Overvoltage and frequency s
135. it is not needed or if the timer has failed The timing circuit is triggered by the same signal thatis usedto drive K1 or K2 The output ofthe tim ing circuit is used to energize Contacts K3 6 K3 9 and contacts K3 4 K3 7 acting in con junction with auxiliary switches S9 and S5 respec tively control the linear actuator circuit When the normally open contacts of K3 close the linear ac tuator circuit is completed and the switch contacts are moved from the neutral position to their original destination Refer to sheets 2 and 5 of your schematic and wir ing diagram package 2 10 Timing amp Delay Seconds Program Transition FIGURE 2 5 PROGRAM TRANSITION MODULE Signal Module The optional Signal Module Figure 2 6 has one adjustable timer The Elevator Signal delay con trols the timing of two events It delays transfer retransfer and energizes the Elevator Transfer Sig nal relay during the delay period This time delay is adjustable over a range of 0 to 50 seconds A Delay No Delay switch permits bypassing the timer delay if it is not needed The timing circuit is started by a transfer or a retransfer signal from the time delay module on the Power Sentry mother board If the transfer switch includes the Signal Module re sistors R10 and R11 on the mother board sche maticin section 8 are removed Because these re sistors are removed the transfer and retransfer sig nals from the time delay modu
136. itch Optional accessories include Battery charger Auxiliary relays Load Shed function Meter package Auto Manual switch 600 Volt adapter transformer T4 Alarm Module FIGURE 2 3 TERMINAL BLOCKS Three Wire Start The 3 Wire Start module Figure 2 4 provides start stop signals and a preheat signal for a three wire start system It includes a preheat timer an overcrank timer an overcrank reset switch an Auto Handcrank Stop switch and three indicator lamps The 3 Wire Start module may be equipped with a preheat timer On Off switch If used the preheat timer delays the start signal 0 to 60 seconds while a preheat output is energized The Preheat Timing lamp is on during this delay The overcrank timer limits the time the engine starter motor is engaged If the generator set does not start within the adjustable time limit O to 120 seconds a relay opens the starting circuit During cranking Overcrank Timing lamp is If the overcrank timer opens the circuit a Lockout lamp is lit After a starting problem is corrected press the Overcrank Reset switch to reset the timer It cannot be reset by any other method The Auto Handcrank Stop switch has three posi tions that function as follows Auto Allows the generator set to start and assume the load if a power outage oc curs This Is the normal operating position Stop Shuts down the generator set and prevents it from starting Use this position when ser
137. k the circuit path to the linear actuator Switch S3 breaks the circuit path to the coil of relay K1 and lights Nor mal Connected lamp on the door Stop Time Delay The stop time delay begins tim ing as soonas the Retransfer Complete lamp lights The stop time delay is adjustable from 0 to 10 min utes The Stop Timingylamp lights while the stop time delay is timing This delay allows genera tor set to cool downmwhilegunning at no load When the stop time delay has timed out provided that K16 is de energized y the time delay module ener gizes the two wire start relay K11 turns off the Start Gen Setlamp and if applicable sends stop signal to the 3 Wire Start module On two wire start systems K11 contacts open re moving the generator set run signal On three wire Start Systems a relay in the 3 Wire Start module signals the generator set to stop After the genera stops the Source 2 Available lamp goes out Test Exercise With Without Load Mother Board 300 3090 To follow this description of Power Sentry control of generator set test and exercise functions refer to the schematic of mother board 300 3090 in sec tion 8 On the schematic locate switch S1 and re lays K11 K12 K13 and K16 Locate the Test Nor Retransfer switch S12 on sheet 2 of the sche matic and wiring diagram package Signal to Test Exercise The signals that initiate test or exercise enter the mother board at e Lo
138. l relays have two normally open and two normally closed contacts thatare rated for 6 amperes at 600 VAC Table 2 2 is a partial list of the auxiliary relay op tions The AC relays are energized by the same signals that power the corresponding indicator lamps on the cabinet door The Emergency and Normal DC relays are ener gized to indicate transfer switch position The Gen set Run DC relay is energized only when the 2 wire start signal is present at the RMT terminal of TB2 Refer to sheet 1 and to the drawings referenced on sheet 3 of your schematic and wiring diagram package Load Shed The optional Load Shed function is used to discon nect the load from an available in order to reduce the power consumed that source The Load Shed function When activated by a customer supplied signal moves the transfer switch from the Emergency position to the neutral position Load Shed signal relay K4is energized by the clos ing of a switch across terminals TB3 29 and TB3 30 When 4 15 energized four sets of K4 con tacts act in conjuncti n with auxiliary switch S8 and relay K2 to linear actuator and move the transfer switch trom the Emergency position to the neutral position When load shedding 15 in effect a return of Normal utility power will Cause retransfer to the Normal power source immediately If the load shed signal is removed before Normal power returns the switch wi
139. l the rod end assembly and tightenthe capscrew to 70 to 75 in Ibs 7 9 to 8 5 Nem Hold the actuator motor in position over the switch assemblies so the lead wires are at the bottom and fitthe rod assembly into the handle of the closed switch assembly Secure the actuator motor to the switch as semblies using hex head capscrews 4 lock washers 4 flat washers 8 and spacers 4 Tighten capscrews to 45 to 50 in Ibs 5 1 to 5 7 Nem Connect the black actuator lead wire to the cir cuit breaker and the red and white actuator lead wires to the following capacitor terminals White Lead Wire If one capacitor connect to C1 Terminal 2 If two capacitors connect to C2 Terminal 2 Red Lead Wire Connect to C1 Terminal 1 Transfer switches for voltage ranges 347 380 416 and 440 480 use two capacitors C1 and C2 wired together In serles A single jumper wire Is placed between terminal 2 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 ac tuator Use wire ties to hold the actuator lead wires in place with the rest of the wiring har ness 1 55 M E gt m z 9 lt ACTUATOR EMERGENCY D TORQUEO 70 TO 75 IN LBS 7 9 TO 8 5 Nem 2 roRQUE TO 45 50 1 LBS 5 1 TO 5 7 Nem 3 TORQUE TO 25 TO 30 IN LBS 2 8 TO 3 4 Nem FIGURE 4 11 TRANSFER SWIT
140. le do not have a di rect pathto relays K14 and K15 Instead these sig nals are directed to the Signal Module and are re turned to drive the relays after the elevator time de lay has elapsed While the timer is timing the form C Elevator Sig nal relay is energized and the Timing lamp on the Signal Module is lit At the end of the time delay the Elevator Signal relay is de energized and the Switch is allowed to transfer When installed on a utility to generator set transfer switch there are four other Signal Module rel ys with form C contacts e Source 1 Available e Source 2 Available e Test Exercise Backup Source Available These relays are not affected by Elevator Signal delay They respond dir ctly to signals from the Power Sentry The Source 1 and Sodrce2 Available relays are en ergized whenev r theif respective power sources are producing power In utility to generator set applications the Source 2 Available Source Available relays op erate identically The Test Exercise relay is energized whenever the system is in test or exercise mode Refento Section 5 or 6 for a description of generator set to generator set or utility to utility signal mod ules Allrelay contact connections are made at TB3 Re fer to sheet 1 of your schematic and wiring diagram package 2 11 amp 16 No Signal Module Delay Delay Timing Delay Seconds Elevator Signal FIGURE
141. lectrical contacts when the cabinet door is open Remove power to the door by disconnecting connector J1 P1 accessory control panel before removing and replacing components 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 Automatic transfer switch operation results rapid movement of the sswitch mechanism and presents a hazard of severe personal injury Keep hands clear of the switch handles when switching to automatic operation TROUBLESHOOTING 3 3 Transfer Switch Does Not Transfer During Power Failure Test or Exercise This procedure Is to be performed with the generator set running and the Test switch in the Test position MAKE SURE THAT THE MOTOR DISCONNECT SWITCH IS IN THE AUTO POSITION NOTE if the Program Transition module Is used and transfer switch only moves to the mid transition disconnected position the trouble may be in Program Transition module orrelay K3 Place the Delay No Delay switch In the No Delay position If transfer occurs replace the Program Transition module If transfer does not occur replace K3 When taking voltage measurements be sure that the probe penetrates the conformal coating on the boards 1 5 the Transfer Timing lamp lit Is Source 2 Available lamp Go to the Source 2 voltage sensor troubleshooting section Is the Transfer Timing Complete lamp on
142. liary switches are configured to respond to the position of the transfer switch When the transfer switch is in the Normal position switches 52 59 54 and S5 are actuated When the transfer Switch the Emergency position switches S6 S7 S8 and S9 are actuated Refer to Section 2 and to the schematic and wiring diagram package for more information on the functions of the individ ual switches The schematic and wiring diagram package is shipped with the transfer switch Contact your dis tributor if you do not have a set of drawings Refer to Section 4 for a description of auxiliary switch maintenance procedures Auxiliary Contacts Auxiliary contacts are provided on the Normal switch 52 and Emergeney switch S6 sides of the transfer switch They are actuated by operation of the transfer switch during transfer and retransfer The Normal side auxiliary contact switch is actu ated when the transfer switch is in the Normal posi tion side auxiliary contact switch is actuated when the transfer switch is in the Emer gency position The auxiliary contacts have current ratings of 10 amperes at 250 VAC ELECTRONIC CONTROL Figure 1 3 shows the interior of a 125 ampere util ity to generator set transfer switch Due to differ ences in cabinet sizes the location of some of the optional modules in your transfer switch may not be the same as shown here Refer to section 5 6 or 7 If applicable
143. ll transfer back to the Emergency side Refer to section 7 for a description of the non automatic transfer switch Load Shed option Refer to sheets 1 2 and 5 of your schematic and wiring diagram package 2 15 FIGURE 2 12 AUXILIARY RELAYS TABLE 2 2 AUXILIARY RELAY OPTIONS 24VAC Coil 24 VAC Coil 24 VAC Coil 24 VAC Coil 24 VAC Coil 24 VDC Coil 24 VDC Coil 24 VDC Coil 24 VDC Coil 12 VDC Coil 12 VDC 12 VDC Coil 12 VDC Coil Installed Not Wired Emergency Connected Relay Normal Connected Relay Emergency Source Available Relay Normal Source Available Relay Installed Not Wired Emergency Relay Normal Relay Genset Run Relay Installed Not Wired Emergency Relay Normal Relay Genset Run Relay The optional meter package includes AC am meter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltages of the selected power source AC Ammeter The ammeter measures the line cur rents of the load Frequency Meter This meter measures the out put frequency of the selected power source in hertz Phase Selector Switch This switch is used to se lect the source and phase to be measured Power to the voltage and frequency meters is sup plied from the connector lugs through connector J1 P1 on the accessory control panel and through the phase selector switch 813 On switches rated for more t
144. ltage and phase dependent Refer to sheet 3 of 5 in your schematig and wiring diagram package Mother Board Assembly Theemother board assembly is a printed circuit board that serves as a central terminal for all the in put and output signals that flow through the control It also provides a mounting point for the voltage sensing and time delay modules and several con trol relays including K11 the two wire run relay Connections to the motherboardare made through five mating locking pin connectors J4 J5 J6 J7 and J8 and three circuit board edge connectors J1 J2 and J3 There are three different mother boards Utility to generator set transfer switches may be equipped with mother board 300 3953 or mother board 300 3090 Utility to utility and generator set to generator set transfer switches are equipped with mother board 300 3267 Mother board Identification Mother board 300 3090 has one With Without Load switch Mother board 300 3953 has two With Without Load switches Mother board 300 3267 does not have a With Without Load switch The schematics of the varlous mother boards ap pear in Section 8 Significant differences are pointed out In this section J1 J2 and J3 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 Emer gency power source Connec
145. ly dangerous conditions Read the manual carefully and know when these conditions exist Thentakethe necessary steps to protect per sonnel and the equipment This symbol warns of Immediate hazards that will result In severe personal Injury or death This symbol refers to a hazard or unsafe practice that can result in severe per sonal Injury or death This symbol refers to a hazard or unsafe practice that can result In personal In jury or product or property damage High voltage in OT transfer switch components pre sents serious shock hazards that can result in se vere personal injury or death Read and follow these suggestions Keep the transfer switch cabinet closed and locked Make sure only authorized personnel have the cabinet and operational keys Due to the serious shock hazard from high voltages within the cabinet all service and adjustments to the transfer switch must be performed only by electrician or authorized service representative If the cabinet must be opened for any reason 1 Move the operation selector switch on the gen erator set or Stop Auto Handcrank switch on the automatic transfer switeh whichever ap plies to Stop 2 Disconnect the starting batteries of the gen erator 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 rubberinsulative mats on
146. mal posi tion The Emergency side auxiliary contact switch is actuated when the transfer switch is in the Emer gency position T he auxiliary contacts have current ratings of 10 amperes at 250 VAC Connections for the auxiliary contacts are made on terminal block TB1 Refer to sheet 1 of your schematic and wiring diagram package ELECTRONIC CONTROL SYSTEM This section describes the standard and optional components of the electronic control system Improper calibration or adjustment of electronic control modules can cause death severe personal Injury and equipment or prop erty damage Calibration and adjustment of these components must be performed by tech nically qualified personnel only Power Sentry calibration and adjustment proce dures are described In section 2 The most important component of the electronic control system is the Power Sentry control Figure 5 3 The Power Sentry includes voltage sensing circuits time delay circuits and control relays There are also several adjustment potentiometers and indicator lamps on the Power Sentry The ad justments must be performed only by qualified service personnel AWARNING Accidental actuation of the linear motor can cause severe personal Injury Dis able the motor as described below before making any adjustments Place the Motor Disconnect Switch Figure 5 3 in the Off position when making adjustments Return the switch to the Auto position after ad justments
147. minals accept wire sizes from one 18 AWG wire to two 12 AWG wires Table 6 1 lists several auxiliary relay options All relays havetwo normally open and two normally closed contacts that are rated for 6 amperes at 600 VAC Figure 6 6 The AC relays are energized by the same signals that power the corresponding indicator lamps on the cabinet door Refer to sheet 1 and to the drawingswreferenced sheet of your schematic and wiring diagram pack age Alarm Module Option The optional alarm module Figure 6 7 provides an audible indication that the transfer switch has trans ferred to the Source 24 source A push button the alarm module provides means to sllence the horn The Alarm lamp indicates that the transfer switch is in the Source 2 Connected position If the horn is sil niced the Horn Silenced lamp will also light Both lamps will stay lit until the transfer switch moves from the Source 2 Connected position to the disconnected neutral or Source 1 Connected position 6 7 TABLE 6 1 AUXILIARY RELAY OPTIONS 24 VAC Coil 24 24 Coil 24 24 installed Not Wired Emergency Connected Relay Normal Connected Relay Emergency Source Available Relay Normal Source Available Relay FIGURE 6 6 AUXILIARY RELAYS FIGURE 6 7 ALARM MODULE OPERATION Automatic Operation The automatic transfer switch is set for automatic operation by pla
148. n addition to start and stop functions the control has crank relay a preheat relay two Timing lamps a Lockout lamp a Reset switch a preheat delay On Off switch and an Auto Stop Handcrank switch Programmed Transition Opti n The optional Program Transition module is used to introduce a pause during transition Programmed transition allows the transfer switch to assume midtransition position adjustable interval of time In this position the load is not connected to either power or Emergency This feature allows residual voltage from inductive loads to decay to an acceptable level before transfer is completed Signal Module Option The main function of the optional Signal Module is to delay transfer or retransfer for a preset time while operating a signal contactto give warning that atfansfer or retransfer is about to occur This op tion is typically used in elevator applications Float Battery Charger Option The optional float charge battery charger regulates its charge voltage to continuously charge without damage to the battery As the battery approaches full charge the charging current automatically ta pers to zero amperes or to steady state load on the battery The battery charger has an ammeter for in dication of charging current and has a fuse for pro tection of the battery charger circuit Auxiliary Relays Option Optional auxiliary relays provide co
149. n the load is neither connected to the Normal power source nor to the Emergency power source This feature allows residual voltage from inductive loads to decay to an acceptable level before trans fer is completed The length of time that the transfer Switch is in the midposition can be adjusted from 0 to 7 5 seconds or to 60 seconds depending on the timer option The proper adjustment is a func tion of the load To set the time delay align the slot on the potenti ometer with the desired marking on the faceplate Figure 6 4 If atime delay is desired make sure that the Delay No Delay switch is in the Delay position Refer to sheets 2 and 5 of your schematic and wir ing diagram package Signal Module Option The optional Signal Module Figure 6 5 has one adjustable timer The Elevator Signal delay trols the timing of two events It delays trarisfer retransfer and energizes the Elevator Transfer Sig nal relay during the delay period This time delays adjustable over a range of 0 to 50 s conds A Delay No Delay switch permits bypassing the timer delay if it is not needed The timing circuit is started by a transfer or retransfer signal from the time delay module on the Power Sentry mother board While the timer is timing the form C Elevator Sig nal relay is energized and the Timing lamp on the Signal Module is lit At the end ofthe time delay the Elevator Signal relay is de energized and th
150. nd B to the pri mary side of T1 it and repair it Unplug P2 while watching Does the relay drop out Either relay K1 on the accessory control panel could be defective or there could be an open in the wiring from J7 6 to K1 There may be an open between K1 9 or K1 7 and the linear motor The circuit breaker CB 1 could be open or defective or the linear motor M1 could be defective CB1 and 1 are located on the transfer switch 3 3 AC power within the cabinet and the rear side of the cabinet door presents shock hazard that can cause severe personal Injury or death The following procedures are to be performed only technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door Is open Remove power to the door by disconnecting connector J1 P1 on theaccessory control panel before removing and replacing components TROUBLESHOOTING 3 2 Source 1 Voltage Sensor Does Not Sense Voltage Place the Test With Without Load switch In the Without Load position When taking voltage measurements be sure that the probe penetrates th conformal coating on the boards 1 Are the proper line voltages present at the Normal lugs of the transfer switch 2 Are the proper line voltages present at transformer assembly terminal block A1 TB11 located below the mother board Refer toysheet 3 of 5 in your schematic and wiring diagram package Is there 15 to 25 VAC
151. ndwidth Timing of Nominal Complete Delay Seconds Frequency Undervoltage Delay Minutes Dropout of Nominal Timing Complete Overvoltage Delay Delay Seconds Seconds FIGURE 2 14 POWER SENTRY ADJUSTMENTS 2 22 ACpower within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door Is open Undervoltage Sensor Calibration The standard voltage sensor modules monitor the Normal and Emergency power sources for an un dervoltage condition To calibrate the undervoltage sensors 1 Check that nominal voltage is present on all phases of the source being calibrated Normal or Emergency On voltage sensors with the frequency sensing option the source fre quency must be within the limits set by the Fre quency Bandwidth potentiometer Turn the Undervoltage Pickup and Dropout po tentiometers on the voltage sensor fully clock wise Turn the Undervoltage calibration Cal poten tiometer fully clockwise The Source Available lamp that corresponds to the source sensor being calibrated should be on If the Source Available lamp fails to come on and th volt age sensor has overvoltage sensing option turn the overvoltage Dropout and Cal potenti ometers fully clockwise Turn the Undervoltage Cal potentiometer counterclockwise
152. nsfer and retransfer of the load are thejtwo most basic func tions of a transfer switch Operation of nonautomatic remote transfer switch is initiated either byan operator at the trans fer switch or by external signal from a remote source 7 1 CABINET The standard cabinet meets the requirements of the National Electrical Manufacturers Association NEMA for a UL Type 1 cabinet Thistypeis desig nated as a general purpose indoor cabinet Items on the door of atypical cabinet are shown in Figure 7 2 Indicator Lamps There are four indicator lamps on the cabinet door The Normal Available and Standby Available lamps are lit whenever their corresponding power sources are producing power These two lamps can be lit simultaneously The Normal Connected and Standby Connected lamps indicate which power source is connected to the load Only one of these two lamps can be lit NORMAL CONNECTED LAMP NORMAL AVAILABLE LAMP PHASE SELECTOR SWITCH FOR OPTIONAL METERS LOCAL REMOTE SWITCH Normal Standby Switch This three position spring return to center switch is used to electrically select which 15 con nected to the load The Normal position causes the Normal source to be connected The Standby posi tion causes the Standby source to be connected Under electrical control the transfer switch will con nect to a source only if voltage isspresent at that source The Normal Standby switch
153. nstall the lug terminals on the block and cross bar assembly and secure with hex head capscrews ring terminals and spring wash ers Tighten to 10 to 12 ft lbs 13 6 to 16 3 Nem torque Install the interlock arm and secure with the two round head capscrews Tighten the screws to 15 to 20 in Ibs 1 7 to 2 3 Nem torque Install the two threaded hex spacers in the back of the block and cross bar assembly On 4 pole switches Figure 4 9 Secure the neutral block with the machine screw that was removed from the center hole Tighten to 70 to 75 7 9 to 8 5 Nem torque Fill the cavity in the block with adhesive silicone to com pletely cover the screw head Pivotthe neutral block to permit placement of the block and cross bar assembly Secure the block and cross bar assembly to the base with the hex head capscrews Tighten to 70 to 75 in lbs 7 9 to 8 5 Nem torque On 4 pole switches Figure 4 9 A Pivot the neutral block back to its correct position Secure the neutral block with the two Phil lips screws and the spacer Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem torque Secure the neutral jumper buSbar withthe hex head capscrew terminal ring spring washer and load lug Tighten to 10 to 12 ft Ibs 13 6 to 16 3 Nem torque Position the neutral block arc chute and cover Securethe arc chute cover with the two matchine screws Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque B
154. nstaller to activate other audible or vis ual alarms An optional harness and Contact block is required Under normal operating conditions the Low Bat and AC Fail relays are energized and the High Bat relay is de energized In response tofa Low Bat or AC Fail condition the appropriate normally ener gized relay Low Bat or AC Fail drops out In re sponse to a High Bat condition the normally de energized High Bat r lay is energized The alarm contacts ate rated for 4 amperes at 120 VAC or 30 VDC Connections to these contacts are made at terminals 41 42 43 AC failure 44 45 46 high battery voltage and 47 48 49 low battery voltage of TB3 Figure 2 11 The high and low alarm and float voltage adjust ments the factory Adjustment proce described later in this section CHARGER 2 12 MVOLY 2 10 FIGURE 2 10 BATTERY CHARGER LINE NC FAILURE NO BATTERY NC VOLTAGE NO FIGURE 2 11 10 AMPERE BATTERY CHARGER ALARM CONTACTS Auxiliary Relays Optional auxiliary relays Figure 2 12 provide con tacts for energizing external alarms remote indica tors and control equipment such as louver motors and water pumps There are three types of auxiliary relay coils 12 VDC 24 VDC and 24 VAC DC relay coils are powered voltage AC relay coils are powered by the 24 VAC outputs of T1 and T2 Al
155. ntacts for ener gizing external alarms remote indicators and con trol equipment such as louver motors and water pumps Exerciser Clock Option The optional exerciser clock initiates generator set start run cycles at programmable intervals and for programmable durations is a 7 day 24 hour clock that can store and execute up toten start stop programs exercise cycles Load Shed Option The optional Load Shed function is used to discon nect the load from an available Emergency source in order to reduce the power consumed from that source The Load Shed function when activated by a customer supplied signal moves the transfer switch from the Emergency position to the neutral position Alarm Module Option The optional alarm module provides an audible in dication that the transfer switch has transferred to the emergency power source Phase Sequence Balance Monitor Option The optional phase sequence balance monitor senses A B and C phases of utility power If there is an over or undervoltage a phase reversal a loss of one phase or an unbalanced voltage condition a normally energized relay drops out initiating the generator set start transfer of load sequence Standby Set Start Sequencer Option The optional standby set start sequencer is avail able only on a generator set to generator set trans fer switch The standby set start sponds to a remote start signal from the utility to gene
156. o Charge Check the battery charger fuses Replace if nec essary with f ses of the correct rating Fuse Am pere ratings shown on the charger faceplate of explosive battery gases Cause severe personal Injury Do smoke orcause any spark or flame while servic Ing batteries Battery Loses Water Th battery charger float voltage could be too high Battery Loses Charge Battery charger float voltage could be too low 6 Utility to Utility INTRODUCTION This section provides information for a transfer switch with an automatic utility to utility control The utility to utility control automatically directs transfer of the load from one utility power source to another providing nearly continuous power Much of the information on theory of operation Power Sentry calibration and troubleshooting in sections 1 2 and 3 is applicable Referto this sec tion 6 for anoverview ofthe utility to utility transfer switch Referto the five sheet schematic and wir ing diagram package that was shipped with the transfer switch for specific information about its configuration Section 4 of this manual covers transfer switch as sembly service procedures for all configurations Transfer Switch Application Transfer switches are an essential part of a bulld ing s standby or emergency power system Normal power source source 1 is backed up by an Emergency power source source 2 A transfer switch
157. o Figures 4 8 4 9 dnd 4 10 for identification of auxiliary switch terminals Place the terminal bracket in position on the base and secure it with the hex head machine screws Tighten to 25 to 30 2 8 to 3 4 Nem torque Place the plastic switch cover in position and secure with machine screws flat washers and self locking nuts Tighten to 25 to 30 5 2 8 to 3 4 Nem torque If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emer gency power source Place the operation se lector switch in the Remote position Test the switch for proper operation and close the cabinet BARRIERS TORQUE TO 10 TO 15 IN LBS 1 1 TO 1 7 Nem FIGURE 4 10 AUXILIARY SWITCH 150 TO 260 AMPERES LINEAR ACTUATOR REMOVAL AND REPLACEMENT 300 to 600 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal Inj
158. oad selector switch must be In the Without position Close the cabinet door within the cabinet and the rear side of the cabinet door pre sents a shock hazard that can cause severe personal death Close the cabinet door Move Test Normal Retransfer switch to Test The generator set should start and run At the end of the test period move the Test Normal Retransfer switch to the Normal posi tion The generator will stop 1 8 5 anticipation of scheduled or automatic gen erator set exercise check that the With With out Load selector switches are in the desired positions Refer to Generator Set 6 Close and lock the cabinet door With Load Standby System Test AWARNING AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury death Use extreme caution to avoid touching electrical contacts whenever the cabinet door 15 open 1 Place the Test With Without Load selector Switch on the Power Sentry control in the With Load position The Test With Without Load selector switch In With Load position In order to test with load Close the cabinet door AC power within the cabinet the rear side of the cabinet door pre sents a shock hazard that can cause severe personal Injury or death Close the cabinet door Move the Test Normal Retrans
159. oducing power These two lamps can be lit simultaneously The Source 1 Connected and Source 2 Connected lamps indicate which power source is connected to the load Only one of these two lamps can be lit Source Selector Switch This two position switch is used to select which source is preferred and which source is the backup SOURCE 1 CONNECTED LAMP SOURCE 1 AVAILABLE LAMP PHASE SELECTOR SWITCH FOR OPTIONAL METERS OPTIONAL AUTO MANUAL SWITCH In the Source 1 position the Normal power so rce supplies the load power until a power interruption occurs In the Source 2 position the Emergency power source supplies the load power until a power inter ruption occurs Optional Auto Manual Switch The optional Auto Manual switchs used to enable or disable the automatic retransfer function This switch has two positions In the Auto position nor mal automatic retransfer is enabled In the Manual position automatic retransfer from the non pre ferred source back t the preferred source is dis abled only manuaf retransfer using the Preferred Source Selector Switch is possible In the event of power source failure however the Power Sentry control logic will gnore the Auto Manual switch and initiate retransferto the other source Whefi the optional Auto Manual switch Is Installed the standard Source Selector Switch Is replaced with three position spring return to center switch SOURCE 2 CONNECT
160. odule Genset 1 Running Genset 2 Running These relaysare not affected by the Elevator Signal delay They respond directly to signals from the Power Sentry The Genset 1 and Genset 2 Running relays are en ergized when their respective power sources producing adequate power 5 10 e Timing e N 2 ro Delay Tille J30 1 Program Transition FIGURE 5 8 PROGRAM TRANSITION MODULE Signal Module No Delay Delay 16 Timing Delay Seconds c Eg o 5 gt FIGURE 5 9 SIGNAL MODULE All relay contact connections are made at Re fer to sheet 1 of your schematic and wiring diagram package To setthe time delay align the slot on the potenti ometer with the desired marking on the faceplate Figure 5 9 If a time delay is desired make sure that the Delay No Delay switch is in the Delay position The Signal Module option Is not available on transfer switches that are equipped with 3 Wire Start mod ules Float Battery Charger Option The optional float charge battery charger Figure 5 10 regulates its charge voltage to continuously charge the battery As the battery approaches full charge the charging current automatically tapers to zero amperes or to steady state load on the battery There are two chargers available One battery charger is rated for 10 amperes at 12 or 24 VDC The other battery charger is rated for 2 amperes at 12
161. of Normal power initiates sev eral control responses that eventually cause the load to retransfer to the Normal side Source 1 Voltage Sensor The Source 1 voltage sensor monitors the Normal power source When the voltage and frequency satisfy the pickup setting requirements the sensor signals that Source 1 voltage is available The Source 1 Available lamp lights and stays on as long as the Normal source voltage is within the voltage and frequency settings of the voltage sensor Retransfer Time Delay The retransfer time delay begins timing as soon as the voltage sensor signals that Source 1 voltage is available The retransfer time delay is adjustable from O to 30 minutes The Retransfer Timing lamp lights while the retransfer time delay is timing This delay allows the line volt age to stabilize before retransferring to the Normal power source Retransfer of Load Afterthe retransfer time delay has timed out the time delay module generates a retransfer signal If the optional Signal Module is not used the retransfer signal energizes the retransfer control relay K15 If the Signal Module is used the retransfer signal is delayed for a preset time 0 to 50 seconds During this delay the Signal Module energizes an Elevator Signal relay to announce that a retransfer is about to occur When K15 is energized with or without the Signal Module delay its normally open contacts close and energize retransfer relay K1 When K1 is ener
162. ollowing procedures cover the removal and replacement of the linear actuator for 40 to 125 ampere switches Removing Actuator 1 Open the transfer switch cabinet door 2 Loosen and remove the four machine screws with flat washers that secure the 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 NORMAL C z uJ o gt ul 2 tc tr gt 2 TENET c E 25 2 SO p 2 QU E do Qo o lt lt lt 9 3 o SN q pees SSeS ae 2 TORQUE 70 TO 75 IN LBS 7 9 TO 8 5 Nem 1 TORQUE 25 TO JOIN FIGURE 4 1 TRANSFER SWITCH COVER 40 TO125 AMPERES 4 2 Pry the capacitor s loose from the bracket Remove the end cap and disconnect the red and white actuator leads from the capacitor and the black lead from circuit breaker Note the lead connections to the capacitor termi nals Remove the socket head capscrews and lock washers that secure the actuator to the block assemblies Figure 4 1 Note the ground wire connection to the lower left capscrew Disengage the actuator rod from the switch handle and remove the actuator from the block assembly Remove one of the hex head capscrews and lock washers that secure the rod end assembly
163. on the mother board between CR20 Cathode and CR24 Cathode CR22 Cathode and CR26 Cathode CR16 Cathode and CR18 Cathode Is there approximately 12 VDC between CR5 anode on the mother board and ground With the voltage sensor removed from slot Jt on the mother board is there 15 to 25 VDC between J1 14 J1 15 J1 16 and ground and 20 to 30 VDC be tween J1 17 and ground If voltages are OK put the board back in slot J1 If the sensor module is equipped with frequency sensing is frequency within limits Recalibrate the sensor module if it can t be calibrated then replace the sen sor module and calibrate the new one Find and repair an openin th wiring between the Normal lugs on the transfer switch and the transformer assembly terminal block located below the mother board Replace the mother board and calibrate the voltage sensors Perform th seteps the following sequence Replace the transformer board to mother board ribbon cable If the source 1 voltage is not sensed replace the transformer assembly and recalibrate the sensors I the source 1 voltage is not sensed replace the mother board and recalibrate the voltage sensors AC power within the cabinet and the rear side of the cabinet door presents a shockhazard that can cause severe personal Injury or death The following procedures are to be performed only technically qualifled personnel Use extreme caution to avold touching e
164. ontrol The Source Available lamp is on to indicate that the mormal power source is within the voltage and frequeficy settings of the voltage sensor The Retransfer Complete lamp is on to indicate that the Control is signaling forthe load to be connected toth normal power source retransfer No other Power Sentry indicator lamps are on The normally energized start relay K11 and the retransfer relay K15 are energized Normal Power Source Interrupted An interruption in power can be defined as not only the complete loss of powepbutalso as any situation where the voltagetor frequency are outside the set tings of the sensor The voltage sensor sponds to all power interruptions by blocking the Source 1 Available signal Source 1 Voltage Sensor The undervoltage sen sor begins timing if the source fails or if the voltage falls below the dropout setting The undervoltage dropout time delay is factory set for 0 5 seconds and is not adjustable Unless power is lost com pletely both the Source 1 Available lamp and the 2 17 Retransfer Complete lamp remain on the timing period If the voltage returns during the 0 5 second delay the sensor resets itself This short delay prevents the time delay module from re sponding during momentary dips in voltage The optional overvoltage sensor begins timing if the source voltage rises above the dropout setting The overvoltage dropout timesdelay is adjustable
165. op eration selector switch to Stop disconnect the battery charger from Its AC power source and disconnect the starting battery negative lead first 4 1 RECONNECTING AC POWER When Finished After all service procedures are completed f a generator is the Emergency power source connect the negative battery cable to the starting battery f applicable connect the bat tery charger to its AC power source e Reconnect the Normal power source and Emergency power source e Place the operation selector switch in the Re mote position AC power within the cabinet and rear side of the cabinet door pre sents a shock hazard that can cause severe personal Injury or death Use extreme cau to avoid touching electrical contacts whenever the cabinet door Is open LINEAR ACTUATOR REMOVAL AND REPLACEMENT 40 to 125 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal Injury or death Disconnect all sources of AC power from the transfer switch before servicing The f
166. or death Use extreme caution to avoid touch Ing electrical contacts when the cabinet door Is open Incorrect setting of the calibration Cal adjustments will result In abnormal opera tion of the transfer switch All adjustments to the sensor modules are made by turning potentiometers with a screwdriver Access to the potentiometers is made through openings in the cover of the Power Sentry control Figure 2 14 Pickup of 5 Nominal Start Cal s Pr opoat Pickup Bandwidth of Nominal 15 Undervoltage o 5 e e Retranster Nominal 195 rz Dropout Cal Overvoltage Transfer 0 Delay Seconds 420 R dS ee A separate voltage sensor is used for each power source They are located one on each side of the time delay module The Source 1 sensor 5 the Normal utility power source The Source 2 sensor monitors the Emergency generator set power source Disable the Linear Motor Accidental of the linear motor can cause severe personal Injury Dis able the motor as described below before making adjustments Place the Motor Disconnect Switch on the acces sory control panelin the Off position when making adjustments Return the switch to the Auto position after adjustmeritS are completed Start Gen Set Pickup of Nominal Delay S conds Cal Timing Dropout Delay of Minutes Pickup Ba
167. out Load selector When this switch is in the With Load position the local test function using the Test switch on the cabinet door includes the transfer of load to the Emergency side When S4 is in the Without Load position the test function starts and runs the gen erator set but does not transfer the load The With Without Load switch es Is are Included only on the utility to generator set transfer switch Switches S2 and S3 are used to select single or three phase operation Relays There are six relays on the 300 3090 mother board and eight relays on the 300 3953 mother board Three are used to send primary con trol signals and the others are used to control logic functions on the mother board itself Relays K10 and K18 are included only on the 300 3953 mother board These two relays are criti calto the operation of with load test and exercise Refer to Control System Operation The K11 two wire run relay responds to a signal from the time delay module When this normally energized relay is de energized K11 contacts 3 and 2 close to send a two wire start signal Note Output connections for two wire starting are made at TB2 on the transfer switch assembly There are 2 two wire start relays on the generator set to generator set mother board The K12 source 2 available relay is energized only when the source 2 sensor determines that Emer gency power is acceptable The opening of K12 contacts 4 and 2 in conjunction
168. oval and replacement of the block and cross bar assemblies for the 300 to 600 ampere switches Removing the Block and Cross bar Assembly Normal or Emergency 1 Remove the linear actuator as described in the Linear Actuator Removal and Replacement section for 300 to 600 ampere switches Remove the hex head capscrews lock wash ers and flat washers that secure the interlock bar to the interlock arm Figures 4 13 and 4 14 and remove the interlock bar Disconnect the control wiring leadsefrom the jumper bus bars Remove the round head shoulder screws and lock washers that secure handle assembly tothe block and cross barassembly and lift off the handle assembly 4 20 5 Remove the control wiring leads from the power source terminals 6 Remove the lug terminal screws and the power supply wires from the lug terminals Remove the lug mounting screws and then removesthe solder less lugs from the switch assemblies 7 Remove the hex head capscrews ring termi nals spring washers flat washers lock wash ers and nuts that secure the j mper bus bars to the load bus bars 8 Remove the hex head capscrews and spring washers that secure the jumper bus barsto the block assemblies and lift off the jumper bus bars 9 Remove four screws lock washers and flat washers that secure the block and cross bar assembly to the base 4 pole switches remove the screw that secures the small bearing brack
169. perly Connect wires from the generator set starting circuit to TB2 3 and TB2 4 If the set still does not cranky then go to Step 9 With the Test Normal Retransfer switch in the Test position is there 12 or 24 if applicable between J7 10 on the mother board and ground Is there 12 24 if applicable VDC between J8 3 located on the mother board and ground There is an open in the wiring from J8 3 on the mother board to TB2 4 on the transfer switch Find and repair it There is an open in the wiring from TB2 2 on the transfer switch to J7 10 on the mother board Find and repair it Replace the mother board and recalibrate the voltage sensors 3 8 AC power within the cabinet and the rear side of the cabinet door presents shock hazard that can cause severe personal injury or death The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door Is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components 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 Ignition of explosive battery gases can cause severe personal Injury or death Do not smoke or cause any spark or flame while servicing batterie
170. procedures to adjust the float voltage Attempting to adjust or test the bat tery charger with a deeply discharged battery can lead to the false conclusion that the charger 15 malfunctioning Always use a fresh fully charged battery when adjusting or testing the charger Always disconnect the battery charger from its AC source remove the char ger s AC Input fuses before disconnecting the battery cables Otherwise disconnecting the cables can result voltage spikes high enough to damage DC control circuits Turn the operation selector for the generator set to Stop and disconnect the starting battery negative lead first The selector switch is located on the generator set control panel on two wire start systems and on 3 Wire Start module on three wire start systems Connect the fully charged battery negative J lead last to the generator set and verify the charge condition with the hydrometer A fully charged lead acid battery will have a specific gravity of 1 260 at 77 F 25 C Connect the voltmeter directly to the battery terminals and measure the voltage Compare the voltage reading with the value shown in Table 2 3 If the voltage is above or below the recommended float voltage open the cabinet door and adjust as specified in step 5 the voltage is correct proceed to step 7 TABLE 2 3 BATTERY FLOAT VOLTAGES Lead Acld Batteries Battery Voltage Float Voltage 12 13 3 24 26 6 Nickel Cadml
171. r Tighten to 70 to 75 in Ibs 7 9 to 8 5 Nem Place the arc chute covers in position over the arc chutes Attempt to close both sides of the transfer switch The interlock assembly must hold one side open so that only one side closes at at time Replace the linear actuator as described in the Linear Actuator Removal and Replacement section for 800 and 1000 ampere switches Follow steps 2 through 10 in the Replacing Ac tuator section Test the switch for proper operation and close the cabinet AUXILIARY SWITCH REMOVAL AND REPLACEMENT 800 and 1000 Amperes If a generator set provides Emergency power turn the operation selector switch to Stop The selector Switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet pre sents an electrical shock hazard that can cause severe personal Injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the auxiliary switch assembly for 800 and 1000 ampere switches Removing Auxiliary Switch Assembly 1 Open the transfer switch cabinet door 2 Remove the hex head capscrew flat washer and lock washer that secure one of the rod end
172. rator set transfer switch by directing a start sig nal from the generator set to generator set transfer switch to the RMT start input of the generatorset that is selected as the preferred source Refer to Section 2 and to Section 5 if applicable Area Protection Remote Test Transfer The transfer switch can be wired with test transfer switch Closure of a Set of contacts across the remote test transfer inputs terminals 7 and 8 of TB2 causes the transfer switch to sense a simu lated utility power failure and Send a start run sig nal to the generator set load is transferred to the generator set when g nerator set power be comes available On 300 3090 mother boards the With Without Load switch must be n the With Load position 300 3953 mother boards this Input Is NOT depend ent upon the position of With Without Load switch Transfer Inhibit Removatof the jumper across terminals 5 and 6 of TB2 prevents the transfer switch from operating Thisyjumper may be removed when the transfer SWItCh is used in a paralleling system If applicable refer to the interconnection drawings that are fur nished with paralleling switchgear 1 7 OPERATION Automatic Operation The utility to generator set automatic transfer Switch is set for automatic operation placing con trol switches in the positions given below The gen erator set mustalso be setfor automatic operation Refer to section 5 6 or
173. referred source voltage sensor 2 7 Nonautomatic Remote INTRODUCTION This section provides information for a transfer switch with a nonautomatic remote control Some ofthe information on theory of operation and troubleshooting in sections 1 2 and 3 is applicable pee Referto this section 7 for an overview of the non automatic remote transfer switch Refertothe five sheet schematic and wiring diagram package that was shipped with the transfer switch for specific in formation about its configuration LOAD Section 4 of this manual covers transfer switch as sembly service procedures for all configurations r Transfer Switch Application Transfer switches are an essential part of a build ing s standby or emergency power system The Normal power source commonly the utility line is STANDBY backed up by a Standby power source often an e electric generating set A transfer switch supplies FIGURE 7 1 LOAD TRANSFER SWITCH the electrical load with power from one of these two TYPICAL FUNCTION power sources The load is connected to mon of the transfer switch Figure 7 1 Under nor mal conditions the load is supplied with power from the Normal source as illustrated If the Normal power source must be interrupted thedoad istrans ferred to the Standby power source When Normal power returns the load should to the Normal power source The tra
174. rom the utility to generator set transfer switchiby directing a start sig nal from the generator set to generator settransfer Switch to the start inp t of the generator set that is selected as the preferred source The standby set start sequencerpermits normal backup set operation if the preferred active set fails The sequencer permits normal changeover clock initiated operation Refer to the system interconnection drawings if ap plicable 5 13 FIGURE 5 13 ALARM MODULE 2l wm D D 6 m mum D mm an km FIGURE 5 14 STANDBY SET START SEQUENCER OPTION Automatic Operation The automatic transfer switch is set for automatic operation by placing control switches in the posi tions given below The generator set must also be set for automatic operation Motor Disconnect Switch on the Accessory Con trol Panel Auto position Source selector switch on the cabinet door Auto position Stop Auto Handcrank switch three wire start Auto position Operation selector switch on engine control two wire start Remote position Manual Operation The transfer switch has operator handles for manu ally transferring the load Use the following proce dure ACpower within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal Injury or death Use extr
175. s TROUBLESHOOTING 3 6 Generator Set Does not Crank for a Power Failure Test or Exercise Using a Switching Ground Three Wire Starting System This procedure Is to be performed with the line voltage available and the TestU Nor mal Retransfer switch In the Test position When taking voltage measurements be sure that the probe penetrates the confor mal coating on the boards Is the battery voltage at approximately 12 VDC Charge or replace the battery Is the Auto Handcrank Stop switch on the 3 Wire Start module in the Auto position Place the Auto Handcrank Stop switch in the Auto position If the generator set does not crank go to Step 5 With the Auto Handcrank Stop switchin the Handcrank position can the generator set be started from generator set control There is a problem with the generatorsSet consult the generator set service manual Place the Auto Handcrank Stop switch in the Auto position Is there a jumper from TB2 GND to TB2 2 There should NOT be a jumper from TB2 2 to TB2 B Install a jumper TB2 GND to TB2 2 If generator set still does not start then go to step 9 Is there approximately 12 VDC between TB3 1 located on the left side of the cabinet and ground Connect the starter battery to TB3 1 Is there B voltage 12 VDC at TB3 4 There is an open in the wiring between TB3 and the generator set Find and repair it 15 the Overcrank Lockout lamp lit
176. s the contacts closed The center position selects program control 5 6 n nn ce e 9 2 elm 5080 Oe JRO GD De D 9 4 FIGURE 5 4 CLOCK Press the button 2 An I 12 appears the upper display window The I is a symbol for closing contacts Press the h button 3 to set the change over hour Press the m button 4 to set the change over minute Press 1 7 button 5 to advance the indica tor bar 13 from 1 to 7 and backto 1 For each day to be selected for changeover press the Q button 7 when the indicator is over the de sired day number 1 represents Sunday For each contact closure time selected In steps 1 to 5 above there must be correspond ing contact opening time Programthe change over clock to hold the contacts closed for five minutes Press the button 2 An O 15 appears in the lower left display window The O is a sym bol for opening contacts Press the h button 3 to set the hour 8 Press the m button 4 to set the minute 10 Press the 1 7 button 5 to advance the indica tor bar 14 from 1 to 7 and back to 1 Press the Q button 7 when the indicator is underthe d sired day number To enter the complete program press the Pr button 8 If all program requirements have been satisfied the display returns to of day If the program requ
177. sing Option Overvoltage frequency sensing are available as a single option Overvoltage Sensing With optional overvoltage sensing the Sources are monitored for an overvolt age condition As with the standard undervoltage sensing the sensors signal the time delay module which controls the transfer or retransfer sequence An adjustable time delay 0 to 120 seconds over rides momentary overshoots in voltage To set this time delay align the slot on the potenti ometer with the desired marking on the Power Sen try cover Overvoltage adjustment and calibration proce dures are described in section 2 Frequency Sensing With optional frequency sensing the sources are monitored for variations in frequency The sensors determine whether the source is within an adjustable bandwidth As with the standard undervoltage sensing the fre quency sensors signal the time delay module which controls the transfer or retransfer sequence An adjustable time delay 0 to 15 seconds allows the controlto ignore momentary dips or rises in fre quency To set this time delay align the slot on the potenti ometer with the desired marking on the Power Sen try cover Change over Clock Option The optional change over clock initiates generator set starting and operation at programmable inter vals When the source selector switch on the cabi net door is in the Auto position the change over clock determines which g
178. sonal Injury or death Use extreme caution to avoid touching electrical contacts when the cabinet door 15 open The transfer switch can be equipped with one or more optional control modules The 3 Wire Start Program Transition and Signal modules have ad justable time delays that mustbe set The exercise clock must be programmed Disable the Lin ar Motor Accidental actuation of the linear motor can cause Severe personal Injury Dis able motors as described below before making adjustments Place the Motor Disconnect Switch on the acces sory Control panel in the Off position when making adjustments Return the switch to the Auto position after adjustments are completed Three Wire Start The 3 Wire Start module has two adjustable timers The Preheat timer delays the start signal to allow preheating the generator set The Preheat timer s range of adjustment is O to 60 seconds If the module has a Preheat On Off switch make sure that it is in the correct position Overcrank timer limits the time that the genera tor set starter is allowed to operate The Overcrank timer s range of adjustment is 1 120 seconds To set the timers align the slots on the potentiome ters with the desired markings on the faceplate Program Transition The Program Transition module has one adjust able timer The Program Transition time delay holds the transfer switch in the neutral position be fore allowing it to compl
179. sources utility or generator set are producing power hese two lamps can be lit simultaneously The Normal Connected and Emergency Con nected amps indicate which power source is con 1 2 nected to the load Only one of these two lamps can be lit Test Normai Retransfer Switch This switch has three positions In the Normal posi tion the transfer switch is set for automatic opera tion Moving the switch to Test sends a start signal to the generator set After the transfer time delay the generator set will assume the load provided that the Test With Without Load switch Figure 1 3 is in the With Load position Moving the switch to Normal causes the load to transfer to the Normal power source after the retransfer time delay To avoid the delay and cause a fast retransfer of the Normal power source move the to the Retransfer position Optional The optionalmetef package includes amme ter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltage of the selected power source AC Ammeter The ammeter measures the line cur rents of the load Frequency Meter This meter measures the out put frequency of the selected power source in hertz Phase Selector Switch This switch is used to se lect the source and phase to be measured On transfer switches with an AC ammeter the load wires mu
180. st each pass through a current trans former Optional Auto Manual Switch Utility to Generator Set The Auto Manual switch is used to enable or dis able the automatic retransfer function This switch has two positions In the Auto position normal auto matic retransfer is enabled In the Manual position automatic retransfer from a functioning generator set back to utility power is disabled only manual retransfer using the Test Normal Retransfer switch is possible In the event of generator set failure however the Power Sentry control logic will ignore the Auto Manual switch and initiate retrans fer to utility power Refer to section 6 for a description of the optional Auto Manual switch on utility to utility transfer switches EMERGENCY NORMAL CONNECTED LAMP CONNECTED AMP NORMAL EMERGENCY AVAILABLE LAMP AVAILABLE LAMP OPTIONAL AC VOLTMETER anzsosnga OPTIONAL AC AMMETER PHASE SELECTOR SWITCH FOR 22 PTIONAL FREQUENCY OPTIONAL METERS XE TUE METER OPTIONAL i TEST NORMAL AUTO MANUAL RETRANSFER SWITCH SWITCH s FIGURE 1 2 UTILITY TO GENERATOR SET TRANSFER SWITCH CABINET EXTERIOR TRANSFER SWITCH ASSEMBLY The transfer switch Figure 1 3 opens and closes the contacts that transfer the load between Normal and Emergency power The transfer switch is me interlocked to prevent simultaneous closing to both power sources The main parts of the transf
181. st hold one side open so that only one side closes at a time Replace the linear actuator as described in the Linear Actuator Removal and Replacement section for 150 to 260 ampere switches Fol low steps 2 through 9 in the Replacing Actuator section Install the power source supply wires and se curely tighten the lug terminals to the torque value specified on the plastic cover Test the switch for proper operation and close the cabinet AUXILIARY SWITCH REMOVAL AND REPLACEMENT 150 to 260 Amperes If a generator set provides Emergency power tum the operation selector switch to Stop The selector switch is located on the generator set control panel Disconnect both the Normal and Emer gency power sources from the transfer switch If there is an external battery charger disconnect it from its AC power source Then disconnect the set starting battery negative lead first AC power within the cabinet sents an electrical shock hazard that can cause severe personal injury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the auxiliary switch assembly for 150 to 260 ampere switches Removing Auxiliary Switch Assembly 1 After disconnecting all sources of AC power open the transfer switch cabinet door 2 Loosen and remove the two self Locking nuts and the two machine screws with flat wash ers that sec
182. t Transfer Source 2 Voltage Sensor Does Not Sense Voltage Generatot Set Does Not Crank Two wire Start Generator Set Does Not Crank Three wire Start 3 1 AWARNING Improper operation of the genera tor set presents a hazard th t can cause severe personal Injury or death Obs rve all safety pre cautions your gen rator set manuals This troubleshooting procedure asks questions that be answered with a YES or a NO The numbers in th YES and NO columns direct you to the next appropriate step An X in the column means th t the step should reveal or correct the problem Inathiseprocedure you are instructed to measure voltages at specific diodes The cathode is the end with the black band The anode is the end without the black band When taking voltage measurements be sure that the probe penetrates the conformal coating on the boards To perform the following procedures you will need to refer to the mother board schematic Section 8 and to the schematic and wiring diagram package shipped with the transfer switch SS GEER ERE PERE PEERED IQ E eS 3 2 AC power within the cabinet and the rear side of the cabinet door presents a shock hazard that can cause severe personal injury or death The following procedures are to be performed only technically qualified personnel Use extreme caution to avoid touching electrical contacts when the cabinet door 15 open Remove power to the
183. t be replaced X X 24 Replace the mother board andyrecalibrate the voltage sensors X X 3 10 4 Transfer Switch Assembly GENERAL This section covers the removal and replacement procedures for the transfer switch assembly There are four separate switch assemblies Each assem bly corresponds to a particular ampere range The four ampere range groups are 40 70 100 125 am peres 150 225 250 260 amperes 300 400 600 amperes and 800 1000 amperes For servicing purposes each transfer switch as sembly can be separated into the following compo nents e Linear Actuator e Block and Crossbar Assembly e Switches A separate section covers the removal and re placement procedures for each major component within a particular range DISCONNECT AC POWER Before beginning any service procedure e generator set provides Emergency power turn the operation selector switch to Stop The selector switch is located the generator set control panel Disconnect all sources Of AC power from the transfer switch e If there is an external battery charger discon nectit from its AC power source Then discon nect the set starting battery negative lead first The transfer switch presents a shock hazard that can cause severe per sonal Injuryor death unless all AC power Is removed Disconnect all sources of AC power fromthe transfer switch before serv Icing Be sure to move the generator set
184. t to cool while running at no load On the utility to utility transfer switch stop time de lay is not applicable Refer to Adjusting Power Sentry Modules in this section for the time delay adjustment procedures Indicator Lamps Mounted at the edges of the voltage sensor and time delay modules and visible through holes in the Power Sentry cover are eight indicator lamps Refer to Table 2 1 TABLE 2 1 POWER SENTRY CONTROL INDICATOR LAMPS LAMP INDICATES Source 1 Available Source 1 voltage is available and within the voltage and frequency settings of the voltage frequency sensor Source 2 Available Source 2 voltage is available and within the voltage and frequency settings of the voltage frequency sensor Start Gen Set The control is signaling the generator set to run This Tamp is dimly or off when both sources are off The control is timing out the generator stop delay end of this delay a stop signal Stop Timing is sentto the generator set and the Start Gen Set and Stop Timing lamps go out Control is timing out for retransfer to Source T power At the end of the timing period the lamp goes out and the Retransfer Gomplete lamp tums on Retransfer Timing Control is signaling for retransfer 19 Source 1 power The Source 1 Available lamp is also on Retransfer Complete Control is timing out for transfe to Source 2 power Atthe end of the t
185. the bracket s NORMAL FANN eRe ar cal rote TE dui 8 pur n ROD END _ ASSEMBLY s il n ACTUATOR EIS ACTUATOR EMERGENCY A B G TORQUE 70 75 IN LBS 7 9 8 5 Nem 2 TORQUE TO 45 TO 50 IN LBS 5 1 TO 5 7 Nem 8 TORQUE TO 25 TO 30 IN LBS 2 8 TO 34 Nem FIGURE 4 6 TRANSFER SWITCH COVER 150 TO 260 AMPERES 4 10 10 Connect the ground wire to the end of the tuator Use wire ties to hold the actuator lead wires in place with the rest of the wiring har ness Check operation of the transfer switch and alignment of the actuator rod by manually opening and closing both the Normal and emergency switch assemblies Place the plastic switch cover in position and secure with machine screws 2 flat washers 2 and self locking nuts 2 Tighten to 25 to 30 in Ibs 2 8 to 3 4 Nem torque If a generator set is the Emergency power source connect the starting battery negative lead last If applicable connect the battery charger to its AC power source Reconnect the Normal power source and the Emer gency power source Place the operation se lector switch in the Remote position Test the switch for proper operation and close the cabinet 411 GROUND BRUSH FIGURE 4 7 LINEAR ACTUATOR 150 TO 260 AMPERES BLOCK AND CROSS BAR ASSEMBLY
186. ther board Refer toysheets 2 4 and 5 of your schematic and wiring diagram package Optional programmed transition relay K3 is used to open the circuit that drives the linear actuator motor M1 for a time determined by the setting of the Pro gram Transition module Refer to sheets 2 and 5 of your schematic and wiring diagram package and to Optional Control Modules and Accessories this section Optional load shed relay K4 not shown is driven by a customer supplied signal and is used to drive the linear actuator motor M1 from the emergency position to the neutral position Referto sheets 1 2 and 5 of your schematic and wiring diagram pack age and to Optional Control Modules and Acces sories ES1691 1 FIGURE 2 2 ACCESSORY CONTROL PANEL Motor Disconnect Switch S1 Motor Disconnect Switch S1 is used to disable the linear actuator motor In the Off position the switch is open In the Auto position the switch is closed Refer to sheets 2 and 4 of your schematic and wir ing diagram package Connectors Accessory control panel connectors J1 J2 and J3 areused to connect the electronic control system to the power terminals auxiliary switch contacts lin ear motor and the terminals of TB2 Disconnecting J1 disconnects all line power from the door Refer to sheets 2 and 4 in your schematic and wiring dia gram package Terminal Blocks Terminal block TB4 provides six AC connection ter minals Refer
187. ting Ifthe unit is equipped withthe Auto Manual Retransfer selector switch lo cated on the door is thesswiteh in the Auto position If the unit doesn t have the switch then go to Step 8 6 Place the Auto Map abRetransfer switch in the Auto position Does the Retransfer Timing lampion the time delay board come on 7 Does the transfer Switch retransfer after the retransfer time delay 8 Replace the time delay board 9 Turnthe retransfer delay pot on the time delay board to minimum coun terclockwise If the Retransfer Timing Complete lamp doesn t come on within a minute then replace the time delay board If the Retransfer Timing Complete lamp does come but the transfer switch still doesn t retransfer then go to Step 10 10 the Motor Disconnect Switch on the accessory control panel Auto position 11 Place the Motor Disconnect Switch in the Auto position If the transfer switch does not retransfer then go to Step 12 W AC power within the cabinet and the rear side of the cabinet door presents a shocKfiazatd that can cause severe personal injury or death The following procedures are to be performed only by technically qualifled personnel Use extreme caution to avoid touching electrical contacts when the cabinet door Is open Remove power to the door by disconnecting connector J1 P1 the accessory control panel before removing and replacing components TROUBLE
188. to the time delay module to override the retransfer time delay On all versions of the mother board the transfer and retransfer inputs are used in conjunction with the optional signal m dule relay board Refer to Optional Control Modules in this section Utility to utility and generator set to generator set mother boards include Source 1 and Source 2 se lect inputs These inputs are wired to the Source Selector switch on the cabinet door Refer to sec tion 5 or 6 Generator set to generator set mother boards may include an optional change over clock input Refer to section 5 Switches There are three switches on the 300 3090 mother board and four switches on the 300 3953 mother board On the 300 3090 mother board Switch S1 is the With Without Load selector When the switch is in the With Load position test and exercise functions include the transfer of load to the Emergency side When S1 is in the Without Load position test and exercise functions start and run the generator set but do not transfer the load On the 300 3953 mother board Switch S1 is the Exercise With Without Load selector When this switch is in the With Load position the exercise function includes the transfer of load to the Emer gency side When S1 is in the Without Load posi tion the exercise function starts and runs the gen erator set but does not transfer the load On the 300 3953 mother board there is a Switch S4 S4 is the Test With With
189. tor J2 provides a me chanicalelectrical connection point for the time de lay module EXERCISE 300 3953 MOTHER BOARD WITH WITHOUT LOAD SELECTOR SWITCH LOCAL TEST ON LOAD SELECTOR FE VOLTAGE SENSOR SWITCH m FA MODULE H VOLTAGE 7 TIME DELAY SENSOR MODULE MODULE PHASE SELECTOR SWITCH S2 PHASE SELECTOR SWITCH S3 TRANSFORMER ASSEMBLY ES1698 2c 2 The schematic of the 300 3953 mother board is on page 8 3 The schematic of the 300 3267 mother board is on page 8 4 The schematic of the 300 3090 mother board is on page 8 5 ON 6 CONTROL ES1690 COVER FIGURE 2 1 POWER SENTRY CONTROL 2 2 Mother Board Circuitry The mother board cuitry serves several functions that are essential for control operation A series of rectifier bridges receive the AC output from the transformer assembly connector J6 and rectify it The rectified voltage 15 to 25 VDC is used as a reference input for the voltage sensors and as a power source for the control electronics The circuitry for the rectifier bridges is shown in the schematics in Section 8 Separate voltage regulator circuits receive the out put from the Normal and Emergency side rectifier bridges and regulate the voltages to a constant value 12 10 5 VDC These circuits provide power for the control relays display lamps voltage sensor modules and time delay module Capacitor C1 is large enough 0 1 or 0 47 farads to provide
190. transfer switch 3 6 AC power within the cabinet and the rear side of the cabinet door presents a shockshazatd that can cause severe personal injury or death The following procedures are to be performed only by technically qualified personnel Use extreme caution to avoid touching electrical contacts wher the cabinet door is open Remove power to the door by disconnecting connector J1 P1 on the accessory control panel before removing and replacing components improper operation of the generator set presents a hazard that can cause severe personal injury or death Observe all safety precautions your generator set manuals TROUBLESHOOTING 3 4 Source 2 Voltage Sensor Does Not Sense Voltage This procedure is to be performed with the generator set running When taking voltage measurements be sure that the probe penetrates the conformal coating on the boards Is there a jumper or some kind of a closed circuit connected between TB2 5 and TB2 6 Install a jumper between TB2 5 and TB2 6 If the voltage sensor is still inop erative go to Step 3 Are the proper generator voltages present at the Emergency lugs of the transfer switch Are the proper generator voltages present attransformer assembly terminal block A1 TB11 located below the mother board Refer to sheet 3 of 5 in your schematic and wiring diagram p ckage Is there 15 to 25 on the mother board between CR29 Cathode and CR33 Cathode CR31 Cathode and CR
191. um Float Voltage Charge 1 38 to 1 45 volts Example Float charge for 10 cell battery should be 13 8 to 14 5 volts 5 Use a small screwdriver to turn the adjustment potentiometer located on charger panel counterclockwise to decrease the float voltage and clockwise to increaseethe float voltage Adjust in small steps five minutes for the voltage to stabilizesbefore making addi tional adjustments AC power Within the cabinet and the rear side of the cabinet door pre sents a shock hazard that can cause severe personal or death Use care when making adjustments to avoid touching electrical contacts When adjustments are complete close and lock the transfer switch cabinet door the voltmeter from the battery ter minals and disconnect the test battery nega 7 lead first from the generator set Reconnect the generator set starting battery negative lead last and place the operation selector switch in the Auto three wire start or Remote two wire start position 2 27 10 Amp Charger Alarm Settings If the battery voltage rises above the HI alarm set ting or drops below the LO alarm 5 90 5 onds the corresponding HI or LO battery alarm LED is lit and a corresponding of form C relay contacts is activated AC power within the cabinet and the rear side of the cabinet door presents a s
192. ume load The load re mains connected to source f unless a source 1 fail ure is sensed In the Source 2 the source 2 generator set has priority t run assume load The load re mains connected to source 2 unless a source 2 fail ure is sensed SOURCE 2 CONNECTED LAMP SOURCE 2 AVAILABLE LAMP OPTIONAL AC VOLTMETER OPTIONAL AC AMMETER OPTIONAL FREQUENCY METER SOURCE SELECTOR SWITCH M1694 3s FIGURE 5 2 GENERATOR SET TO GENERATOR SET TRANSFER SWITCH CABINET WITH OPTIONS Eo Optional Meter Package The optional meter package includes an AC amme ter an AC voltmeter a frequency meter and a phase selector switch AC Voltmeter The voltmeter measures line to line voltage of the selected power source AC Ammeter The ammeter measures the line currents of the load Frequency Meter This meter measures the out put frequency of the selected power source in hertz Phase Selector Switch This switch is used to se lect the source and phase to be measured Ontransfer switches with an AC ammeter the load wires must each pass through a current trans former TRANSFER SWITCH The transfer switch Figure 5 3 opens and closes the contacts that transfer the load between 1 and source 2 generator sets The transferswiteh is mechanically interlocked to prevent simultane ous closing to both power sources The main parts of the transfer switch discussed here the con
193. until the Soufce Available lamp turns off Slowly turn the Undervoltage Calypotentiome ter clockwise until the Source Available lamp just turns on again The undervoltage sensor is now calibrated If the overvoltage sensor was adjusted in Step 3 then recalibrate it by using the overvoltage sensor calibration procedure Undervoltage Pickup and Dropout Adjustments Undervoltage dropout occurs when an undervol tage condition is sensed Pickup occurs when an acceptable voltage is sensed Undervoltage drop out and pickup are adjustable over the following ranges Function Adjustment Range Pickup 85 to 100 of nominal voltage Dropout 75 to 98 of pickup voltage 2 23 To set the pickup and dropout percentagespalign the slots on the potentiometers with the desired markings on the Power Sentry cover Gigures2 1 4 Overvoltage Sensor Calibration The optional overvoltage sensor monitors the source voltage for an overvoltage condition To calibrate the overvoltage sensor If the undervoltage sensohhas not been calibrated do so before proceeding 1 Check that nominal voltage is present on all phases of the source being calibrated Normal or Emergency On voltage sensors with the sensing option the source fre quency must be within the limits set by the Fre queneysBandwidth potentiometer Turn the Dropout and Delay potentiometers fully counterclockwise gt Tunn the
194. ure the plastic switch cover to the switch base and lift off the cover 3 Remove the three machine screws that secure the terminal bracket Figure 4 6 to the base Move the terminal bracket to allow access to the auxiliary switches 4 Remove the control wiring leads from the auxil iary switch terminals Figure 4 10 5 Remove the hex head machine screws that se cure the auxiliary switch assembly bracket to the base 6 Lift out the auxiliary switch assembly 7 Remove the hex head capscrews and nutsithat secure the auxiliary switches to the brackets Figure 4 10 and lift out the four auxiliary switches and insulating barriers Replacing Auxiliary Switch Assembly 1 Install the insulating barriers 5 and auxiliary switches 4 in the brackets and secure with hex head machine screws 2 nuts 2 Tighten to 10 to 15 in Ibs 1 1 to 1 7 Nem Note that each switch must be assembled so the side with two terminals faces inward Figure 4 10 when the auxiliary switch assembly 15 in stalled on the base Hold the auxiliary switch assembly in position on the base the side with two terminals must face inward and secure 4 to the base using the hex head machine screws Tighten to 25 to 30 imelbs 2 8 to 3 4 Nem torque Install the control wiring leads on the corre sponding switch terminals Leads are marked with the terminal numbers S2 NO S5 NC S7 C etc for identification Refer t
195. ury or death Disconnect all sources of AC power from the transfer switch before servicing The following procedures cover the removal and replacement of the linear actuator for 300 to 600 ampere switches Removing Actuator 1 Open the transfer switch cabinet door 2 Loosen and remove the four machine screws that secure the plastic switch cover to the transfer switch and lift off the cover Figure 4 11 Separate the actuator lead wires from the rest of the wiring harness remove wire ties as re quired Pry the capacitor s loose from th bracket Remove the end cap and diSconnect the red and white actuator lead wires from the capaci tor terminals Disconnect the blackgactuator lead from the circuit breaker and the ground wire from the end of the actuator Remove the hex head capscrews flat wash ers and lock washers that secure the actuator to the switch ssemblies Figure 4 11 Disengageythe actuator rod from the switch handle and remove the actuator from the switch assembly 4 17 8 Remove one of the hex head capscrews and lock washers thatsecure the rod endassembly to the end of the actuator rod 9 Remove the rod end assembly Figure 4 11 and slide the actuator rod out of the actuator motor Replacing Actuator 1 Insert the actuator rod into the replacement ac tuator motor 4 12 Hold the actuator ground brush up slightly to allow passage of the actuator Instal
196. vement perform the following basic functions 1 Sense the interruption of the Normal power source 2 Senda start signal to the generator set Emer gency power source 3 Transfer the load to the Emergency power source 4 Sense the return of the Normal power source 5 Retransfer the load to the Normal power source 6 Send a stop signal to the generator set MODEL IDENTIFICATION Identify your model by referring to the Model and Specification number as shown on the nameplate Electrical characteristics are shown on the lower portion of the nameplate which is located on the cabinet door Referto the last page of this section for a list of feature option codes If it is necessary to contact a dealer or the factory regarding the transfer switch always give Com plete Model Specification and Serial number as listed on the nameplate This information is neces sary to properly identify your unit among the many types manufactured CABINET The standard cabinet meets the requirements of the National Electrical Manufacturers Association NEMA for a UL Type 1 cabinet This type is desig nated as a general purpose indoor cabinet The door of a typical utility to generator set cabinet is shown in Figure 1 2 Refer to section 546 of 7 If applicable Indicator Lamps There are four indicator lamps on the cabinet door The Normal Available and Emergency Available lamps ar litwhenever their corresponding power
197. vicing the gen erator set Handcrank Prevents the automatic transfer switch from starting the generator set but allows st rting and stopping at the set Use thlS position for generator set maintenance Connections for theyoptional 3 Wire Start module are made TB3 Generator set to generator set transfer switches can be equipped with two 3 Wire Start modules Re fer to section 5 Refer to sheets 1 and 5 of your schematic and wir ing diagram package Auto Handcrank Reset FIGURE 2 4 3 Wire Start Timing 6 or sean Seconds 9 60 g n Timing Delay Seconde Overcrank 120 Lockout 6 3 WIRE START Programmed Transition The optional Program Transition module Figure 2 5 is used to introduce a pause during transition Programmed transition allows the transfer switch to assume a midtransition position for an adjustable interval oftime In this position the load is not con nected to either Normal or Emergency power source This feature allows residual voltage from inductive loads to decay to an acceptable level be fore transfer is completed The length of time that the transfer switch is in the midposition can be adjusted from O to 7 5 seconds 0 to 60 seconds depending on the timer option The proper adjustment is a function of the load de cay time A Delay No Delay switch permits bypassing the timer delay if
198. with test or exer cise with load signals helps simulate a loss of Nor mal power for test and exercise purposes If Emer gency power fails during a test or exercise the clos ing of these contacts initiates retransfer to the Nor mal power source K12 relay Is Included only on the utility to gen erator set mother board On the 300 3090 mother board the K13 test exer cise relay is energized by a signal at the test exercise inputs When K13 is energized its con tacts 2 open This action de energizes K11 starting the generator set On the 300 3953 mother board the test exer cise relay is energized by a signal at one of the test exercise inputs only wh n the Corresponding With Without Load switch is in the Without Load position When K13 is energizedyits contacts and 2 open This action de energizes starting the genera tor set K13 relay Is Included only on the utillity to gen erator set mother board The 14 and K15 transfer and retransfer relays are energized by signals from the time delay module When nergized their contacts and 4 close to provide power to one of the interposing relays K14 drives the K2 transfer relay K15 drives the K1 2 4 retransfer relay K1 and K2 are located on the ac cessory control panel The K16 run interlock relay is energized whenever the transfer switch is in the Emergency position When energized its contacts 2 and 4 are open
199. z essor A044 BO Herz oria E ey A045 Voltage 120 NAC Ls de xxt e 020 RO21 220 uud tuU R022 240 5 55 a R023 380 VAC 0 024 416 VAC R025 480 4 f R026 600 amp R027 Phase System 1 Phase 2 W 3 A041 System Phase Wr 4 W A042 Control Options Start Time Delay 90 Sec C015 Control OV 8 O U Hz Source2 C016 Control 8 Hz Source 1 C017 Meters Meters None 0001 Meters Door Mounted 0002 Program Transition Program Transition 0 7 5 Sec J021 Program Transition 0 60 Sec J022 1 11 FEATURE FEATURE DESCRIPTION OPTION Battery Chargers Battery Charger 2A 12 24V KOO1 Battery Charger 10A 12V K002 Battery Charger 104724 K003 Auxiliary Relays Aux Relay 24 VAC Coll 1001 Aux Relay Emergency Position 1002 Aux Relay Normal Position 1003 Aux Relay Emergency Source 1004 Aux Relaye Normal Source 1005 Aux 24 VDC Coil L101 Aux Relay Emergency Position L102 Aux Relay Normal Position L103 Aux Relay Genset Start L104 Aux Relay 12 VDC Coil L201 Aux Relay Emergency Position L202 Aux Relay Normal

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