913-0104B Onan RST-series 60-100
Contents
1. o o GROUNDING CONTACTOR NEUTRAL LUGS ASSEMBLY BAR FIGURE 2 2 INTERIOR COMPONENTS Redistribution or publication of this document 2 2 by any means is strictly prohibited ELECTRONIC CONTROL SYSTEM This section describes the components of the elec tronic control system Improper calibration or adjustment of the electronic control can cause death se vere personal injury and equipment or property damage Calibration and adjustment of these components must be performed by technically qualified personnel only All calibration and adjustment procedures are de scribed in the Installation manual included with the transfer switch and in the Service manual avail able through your distributor The control Figure 2 2 includes voltage sensing circuits time delay circuits control relays and sta tus indicator lights There are also several adjust ment potentiometers and indicator lamps on control package B The adjustments must be performed by qualified service personnel only 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 when the cabinet door is open Control Time Delays The time delay settings on control package A are preset The time delay2. FIGURE 6 SETTING THE YEAR Press the or buttons until the correct year is displayed Press the OK button The day and month will then be displayed with the day flash ing and D M Y is displayed with the D under lined See Figure 7 FIGURE 7 SETTING THE DAY AND MONTH Press the or buttons until the correct day 1 thru 31 is displayed Press the OK button The month value will then flash and D M Y will be displayed with the M underlined Press the or buttons until the correct month 1 thru 12 is displayed Press the OK button The summer winter changeover menu is dis played with the selected region flashing see Figure 8 Redistribution or publication of this document by any means is strictly prohibited FIGURE 8 SUMMER WINTER CHANGEOVER MENU 6 To set the clock for summer winter changeover daylight savings time press the or buttons to select the appropriate region see Table 1 and then press the OK button The home menu is redisplayed The matching number for the current day of the week will be underlined Examples 1 Monday 7 Sunday NOTE If you do not wish any changeover se lect the nonE setting If you wish to set changeover times different from one of the preset times select Mm and follow the instructions included in Table 1 TABLE 1 SUMMER WINTER CHANGEOVER INFORMATION Beginning of End of Country Last Sunday in US October No c
3. FIGURE 13 DELETE PROGRAM MENU 8 Copy the set program set an additional exer cise period or exit the the program input a If you wish to copy the set program see To copy an exercise program in the next col umn Page 6 of 8 b If you do not wish to set any additional exer cise periods press the MENU button until the home menu is redisplayed NOTE On the day that the exercise is to be come active segments will be dis played around the clock showing when the exercise period is set see Figure 14 gt 24 i E 18 E I Gu 1234567 8 SD 12 O Salio A FIGURE 14 SET EXERCISE To copy an exercise program 1 Once a set exercise program has been saved press the selector button to display the copy menu see Figure 15 PROG NEW 2 24 Pr m iah T 6 1234567 AE ai FIGURE 15 COPY EXERCISE MENU 2 Press the button to select the day of the week that you wish to include the same exercise peri od Press the OK button 3 If you want the exercise to occur on additional days repeat the copy procedure 4 To terminate setting exercise programs press the MENU button until the home menu is redis played Redistribution or publication of this document by any means is strictly prohibited To erase delete exercise programs 1 Press the MENU button The selector button Ca will pointing at PROG Press the OK button 2 The selector button will
4. Mains Failure If the clock is disconnected from AC power or the AC power source fails no U is displayed see Figure 21 ron ow FIGURE 21 AC POWER FAILURE INDICATION Redistribution or publication of this document by any means is strictly prohibited Table of Contents TITLE PAGE SAFETY PRECAUTIONS 500207 ai AA AS O ee Be iii 1 INTRODUCTION css ccscevecarshcaedeaintscontuaacarecheceent lo ra 1 1 Transfer Panel Application iden ae ede wtees tiet ede cia add tes seaae sree eeaweaes 1 1 Automate Transter Pa o sa A A ADA AAA 1 1 Model SAUCE A Rasa neers A ee gas 1 1 Float Battery Charger sucia bib as Galo E edad eed od oe hee ead 1 1 OPUIONS Loussier tr s sta Sta te 1 2 EXGICISeMGlOGK A bidet bath aud E AEE aE ele a aaa De Saas Mae es 1 2 io AA A A A ake a Pe tk 1 2 How to Obtain SIC a a leida 1 2 2 DESCRIPTION 2 20 ii eee e ee tS ee aie 2 1 e A A At MO ON aig OOOO 2 1 CAM Dr A Meets web a ein wah aes eee A A athe 2 1 Auto Manual Wicho ek tess Sie ned eas cree Yue ae eee ey ce aN et a ee 2 1 Load No Load Switch yesss ternis ioe Ges neta ale 2 1 3 Phase 1 Phase Switch Control Package B Only 0 0 0 cece eee eee 2 1 IAS RS WII SS A A E tart cae N 2 2 Contact Assemblies cos aiii es les a dd ia aa 2 2 Auxillary Contacts ts NN E E A ts 2 2 Electronic Control System pronta ro re paria 2 3 Control Time Delays seat ieee tite i a ee 28 a ad e tet 2 3 Undervoltage Sensing 2 0 0 6 ee deee d bea eed See eee bea eae
5. by any means is strictly prohibited GENERATOR SET CONTINUES TO RUN AFTER RETRANSFER OF LOAD TO NORMAL POWER 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 The stop time delay function may not have expired Check the Stop Timing lamp on the control Figure 2 2 Stop the generator set with its Start Stop switch and call your dealer or distributor BATTERY CHARGER FAILS TO CHARGE IF EQUIPPED 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 4 3 Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any spark or flame while servicing bat teries Check the battery charger fuse s Replace if nec essary with fuses of the correct rating Fuse am pere ratings are shown on the charger faceplate If the fuse is OK call your dealer or distributor BATTERY LOSES WATER The battery charger float voltage could be too high if equipped with battery charger Call your dealer or distributor BATTERY LOSES CHARGE Battery charger float voltage could be too low if equipped with battery charger Call your dealer or dist
6. be pointing at PROG NEW Press the OK button again 3 Use the or buttons to select the day of the week that the exercise is set When the correct day is selected segments will be displayed around the clock showing when the exercise period is set and CI r is displayed in the center of the clock see Figure 16 4 Press the OK button The clock will be reset to midnight 0 00 and new exercise settings can be entered If you do not wish to set up a new exercise period press the MENU button until the home menu is redisplayed e FF ighh F 1234567 e 12 a Sannat FIGURE 16 DELETING THE EXERCISE PROGRAM To check the exercise program 1 Press the MENU button The selector button Ca will pointing at PROG Press the OK button 2 The selector button Ca will be pointing at PROG NEW Press the selector button button again so that it points to TIME CHECK Press the OK button 3 Use the or buttons to select the day of the week that the exercise is set to begin Press the OK button 4 Repeatedly press the OK button to view the ex ercise starting and stop times A clock is dis played showing the exercise start and stop times NOTE If no exercise periods are set FrEE is displayed instead of the time TIME CHECK ON 2 24 A 18 Lib Gu 1234567 4 12 s8 O ES FIGURE 17 CHECKING THE EXERCISE START TIME 5 To terminate checking the exercise program press he MENU bu
7. generator set does not start within the adjustable time limit 0 to 120 sec onds In order to protect the starter motor over crank relay contacts open the starting circuit and light the Lockout lamp After a starting problem is corrected pressing the Overcrank Reset switch re sets the circuit Refer to the Operation Section A set of overcrank alarm contacts are also provided The contacts can be used to energize an external overcrank alarm 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 If a preheat delay is desired make sure that the Pre heat timer s On Off switch is in the On position To set the timers align the slots on the potentiome ters with the desired markings on the faceplate Fig ure 2 3 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 servicing the gener ator 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 Connections for the optional 3 Wire Start module are made at TB3 3 Wire Start Auto Handcrank Stop
8. 1 INDICATES EXERCISE PERIOD ON FIGURE 4 1 EXERCISER CLOCK GENERATORS STARTS UNEXPECTEDLY DURING NORMAL POWER SERVICE 1 Two wire starting only for water cooled gen erator sets The operation selector switch on the generator set control panel should be set at Remote AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death Use extreme cau tion to avoid touching electrical contacts whenever the cabinet door is open 2 Three wire starting only for air cooled gen erator sets The Auto Stop Handcrank switch on the 3 wire start module should be set at Auto 3 If present check the exerciser clock to see if it is in an exercise period When the exerciser clock is in an exercise period the On mode is indicated in the ellipse in the upper right corner of the display and the genset should be running Figure 4 1 If the exercise period occurs at an unexpected time or for an excessive duration refer to the ex erciser clock programming procedure in Sec tion 2 or call your dealer or distributor Redistribution or publication of this document by any means is strictly prohibited 4 Momentary voltage dips might cause voltage sensors to initiate generator set starting If the problem persists call your dealer or distributor GENERATOR SET DOES NOT EXERCISE 1 Two wire starting only The op
9. 10 Timing off E on Delay Seconds Timing Delay Seconds Overcrank o 120 Reset Lockout SC1573 2s FIGURE 2 3 3 WIRE START MODULE Redistribution or publication of this document by any means is strictly prohibited FLOAT BATTERY CHARGER OPTION A float charge battery charger Figure 2 4 regu lates its charge voltage to continuously charge with out damage to the battery As the battery ap proaches full charge the charging current automat ically tapers to zero amperes or to steady state load on the battery The battery charger is rated for 2 amperes at 12 or 24 VDC and has an ammeter to indicate charging current and a fuse to protect the battery charger cir cuit 2 5 BATTERY CHARGER 2 AMP 12 24 VOLT 2 du FLOAT VOLTAGE ADJUSTMENT 2 AMP CHARGER FIGURE 2 4 BATTERY CHARGER Redistribution or publication of this document by any means is strictly prohibited EXERCISE CLOCK The exercise clock is optional on RST Transfer Pan els with control package A and is standard equip ment on RST Transfer Panels with control package B The exerciser clock is used to start and run the gen erator set at programmable intervals and for se lected durations It is a 7 day 24 hour clock that can store and execute up to four start stop programs per day one minute minimum duration The exerciser clock also has a test feature that can be used to initi ate a genset start and run cycle Pr
10. CIRCUIT BOARD EXERCISER CLOCK LOCATED BEHIND COVER CONTROL PACKAGE B ONLY CONTROL cy side may or may not be mechanically held de pending on the options selected A mechanical in terlock prevents them from closing to both power sources at the same time Auxiliary Contacts Auxiliary contacts are provided on the Normal and Emergency 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 Emergency side auxil iary contact switch is actuated when the transfer switch is in the Emergency position The auxiliary contacts have current ratings of 10 amperes at 600 VAC AUTO MANUAL SWITCH LOCATED ON CIRCUIT BOARD CONTROL STATUS INDICATOR LEDS LOCATED ON CIRCUIT BOARD J1 P1 CONNECTOR BOARD COVER AA 3 PHASE 1 PHASE SWITCH LOCATED BEHIND COVER CONTROL PACKAGE B ONLY OPTIONAL EXERCISER CLOCK CONTROL PACKAGE A OPTIONAL 3 WIRE START BATTERY CHARGER
11. ERCRANK REST 3 WIRE START ONLY An overcrank condition exists when the 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 reset the auto matic starting circuit 1 Correct the engine starting problem 2 Push the Overcrank Reset button inward and release to reset the overcrank relay Redistribution or publication of this document by any means is strictly prohibited PLANNED MAINTENANCE Performing the yearly maintenance procedures in Table 3 1 will help achieve operational reliability of the transfer switch The following procedures must only be performed by trained and experienced personnel fol lowing the procedures provided in the Service Manual 913 0505 If repair or replacement of components is necessary call your dealer or distributor 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 re placement can result in severe personal injury death and or equipment damage Therefore all cor rective service procedures must only be performed by trained and experienced personnel following the procedures provided in the Service Manual 913 0505 The transfer switch presents a shock hazard that can cause severe personal injury or death unless all AC power is removed Be sure to move the generator
12. G TIMES PROG DATE NEW OFF FrEE DAYS WHEN NO EXERCISE _ SU Wi D M Y PERIOD IS SET solos SYMBOL FOR AUTOMATIC OPERATION ACTUAL DAY OF THE WEEK Ya A 07 OR PROGRAM DAY Es rin rhe SYMBOL FOR MANUAL OVERRIDE CA a SYMBOL FOR CONTINUOUS OVERRIDE ON SEGMENT DISPLAY OF THE 1234567 2 lt EXISTING PROGRAM Y Ow 1 SEGMENT 30 MINUTES FO SYMBOL FOR CONTINUOUS OVERRIDE OFF e AS MENU BUTTON ACTIVATES M EXERCISE STATE THE MENU OR BREAKS O ACTIVE OFF THE PROCESS Cox O INACTIVE a ii OK BUTTON CONFIRMS SELECTOR BUTTON X Fa THE INPUT AND SAVES THE CHANGES MINUS AND PLUS BUTTONS THESE SYMBOLS ARE NOT CHANGE THE VALUES INCLUDED ON THE CLOCK FIGURE 3 FIVE BUTTON EXERCISER CLOCK FEATURES Redistribution or publicatio El ES ent by any means Pe ge y pro ed To reset the exerciser clock The clock is not pre programmed The clock can be reset to erase just the existing day and time settings or it can be reset to erase all existing day time and exercise program settings e To erase just the existing day and time settings simultaneously press the MENU and but tons The screen will go blank When the buttons are released two sets of dashes will be momen tarily displayed and then the clock is dis played with the time set to midnight 0 00 e To erase all existing day time and exercise pro gram settings simultaneously press all five but tons
13. Onon Operator s Manual RST 60 100 200 Automatic Transfer Panel Printed U S A 913 0104B 9 2004 Redistributio ee ee sie of this t a stric o ohibite de Supplement 913 1116 Date 12 2004 Insert with Titles LT LC and RST Operator s Installation and Service Manuals Numbers 913 0102 dated 5 1996 913 0103 dated 5 1999 913 0104B dated 9 2004 913 0503 dated 2 1997 913 0504 dated 10 2001 913 0505B dated 9 2004 913 0600B dated 2 2003 913 0601 dated 2 2003 913 0602B dated 9 2004 PURPOSE This supplement updates the LT LC and RST Operator s Installation and Service Manuals to in clude information on the 5 button exercise clock available on current production units SUPPLEMENT USE Write Refer to Supplement on the pages of the manuals listed above that refer to the exercise clock Insert this supplement inside the front cover of the manuals listed above ae Page 1 of 8 Redistribution or publication of this document by any means is strictly prohibited Page 2 of 8 Redistribution or publication of this document by any means is strictly prohibited FIVE BUTTON EXERCISE CLOCKS NOTE After one minute of button inactivity the home menu see Figure 2 will be redis played and any changes made that weren t saved by pressing the OK button will be lost Figure 3 also shows the following clock features e The available menu topics are displayed at the top of the screen e When being progr
14. The screen will go blank Release the MENU button while continuing to press the other buttons Two sets of dashes will be displayed After three seconds have passed re lease the remaining four buttons The clock is then displayed with the time set to midnight 0 00 To set the time 1 With the exerciser clock powered press the MENU button Use the selector button Ca to se lect SET TIME which is displayed in the upper left corner of the display see Figure 4 SET TIME FIGURE 4 SETTING THE TIME 2 Press the OK button The word DATE is dis played Press the OK button again The time is displayed with the hour value flashing The time displayed is based upon a 24 hour clock mili tary time Example 2 00 PM 14 00 3 Press the or buttons until the correct hour is displayed Press the OK button The minute value will then flash 4 Press the or buttons until the correct minute is displayed Press the OK button The home menu is redisplayed showing the set time see Figure 5 Page 4 of 8 124 ha UE 18 BS 6 1234567 e q9 O FIGURE 5 SET TIME To set the date and summer winter changeover deg Press the MENU button Use the selector but ton Ca to select SET TIME and press the OK button Press the selector button to select DATE and then press the OK button The current year is displayed flashing and D M Y is displayed with the Y underlined see Figure 6
15. ad No Load Switch The Load No Load switch is located on the control circuit board Figure 2 2 During a test or exercise cycle the generator set will assume the load if this switch is set to Load If the switch is set to No Load 2 1 the genset will start but the load will not transfer to the generator set 3 Phase 1 Phase Switch Control Package B Only Control package B has a 3 Phase 1 Phase switch located on the control circuit board When the nor mal source is three phase the switch must be set to the 3 phase position for proper voltage sensing For a single phase normal source the switch must be set to 1 phase Onon Transfer Switch FIGURE 2 1 RST CABINET Redistribution or publication of this document by any means is strictly prohibited TRANSFER SWITCH The transfer switch opens and closes the contacts that transfer the load between Normal and Emer gency power The transfer switch is mechanically interlocked to prevent simultaneous closing to both power sources The main parts of the transfer switch discussed here are the contact assemblies and auxiliary contacts Contact Assemblies The automatic transfer switch comes in a three pole configuration only and is provided with a neutral bar The contact assemblies make and break the cur rent flow When closed to the Normal power source the contacts are mechanically held The Emergen LOAD NO LOAD SWITCH LOCATED ON
16. ammed indicators for change over SU Wi and the date D M Y are displayed FIGURE 1 FIVE BUTTON EXERCISER CLOCK beneath the menu topics Figure 3 shows the five operator buttons e The clock displays the time and the day of the week 1 Monday e The Menu button 9 is used to activate a menu or to break off the process e Around the clock are segments showing when an exercise period is set e The Selector Arrow button Ca is used to select E menu topics and one of the four available modes e Near the right bottom corner is a circle indicating of operation Automatic Operation Manual Override Y Continuous Override On O and Continuous Override Off O NOTE There is an audible click whenever an ex ercise period starts or stops the exercise state black active white inac tive NOTE The mode symbols are not included on the right side of the display see Figure 2 They are included in this document for reference pur poses only The button must point to the rela 24 tive position of the symbol shown in this docu E mnn ment to select the desired mode see Figure 3 18 M 6 1234567 e The OK button cx is used to save changes e12 O e The G and buttons are used to change val ues FIGURE 2 EXERCISER CLOCK HOME MENU SUMMER WINTER INDICATOR MENU TOPICS REAL TIME SWITCHING TIME CLR DELETE SWITCHING TIMES WN SA SET TIME CHECK ON DAY MONTH YEAR COPY COPY SWITCHIN
17. ar in the upper left corner of the dis play Figure 2 7 The current program will be over ridden and the clock will automatically set for the next program Momentarily pressing the set button again will return to the current program Permanent On Off Mode Holding the set button down until a flashing hand appears in the upper left corner of the display initiates the permanent On Off mode Figure 2 7 The On mode is indicated by a continuous band of segments illuminated around the clock The Off mode is indicated by all of the segments around the clock being off Pressing the set button momen tarily toggles between the permanent On and per manent Off modes Holding the set B button down until the clock symbol returns to the upper left cor ner of the display ends the continuous On Off mode and returns to the normal program mode Redistribution or publication of this document by any means is strictly prohibited 3 Operation AUTOMATIC OPERATION The basic operation of the transfer switch is auto matic and does not require operator involvement The transfer switch automatically starts the genset on interruption of Normal power and transfers the load circuit when proper genset voltage is reached When Normal power is restored the transfer switch automatically transfers the load back to the Normal source and stops the genset For automatic operation place control switches in the positions given below
18. cals Bede bee 2 3 TWO WIG Stang ro of ogee teed ath cee e Peak wee eek ee eee 2 3 Remote TeSt ls eii pe in Se SAA we ee eee SG i ee 2 4 Three Wire Starting Option a sc sos iver ce rl aa 2 4 Float Battery Charger Option 0 0 0 c cece tenet eee 2 5 Exercise Clock onerosa ba a A aie 2 6 To Reset the Exerciser Clock oir AAA A Aad 2 6 To Set the Day and UM o a ee PO A ee ee 2 6 To Set the Exercise Start and Stop Time 0 0 cece eee tees 2 6 To Check the Programs 00 cece cee ene eee eee 2 7 To Erase Clear a Program 00 ccc eee e teens 2 7 To Initiate or Override an Exercise Program 0 000 cece teens 2 8 Permanent On Off Mode ida eee let Ee a eels eee a 2 8 3 OPERATION nie ea oa hea oe aaa oo Geen se a a aa a ene oe eee e 3 1 A tomatic Opera viscosa eee a E ed eid bea A dd ota ed 3 1 Generator Ser Exercise dado aed veloute ERES EEN Meda ween au Roe eae ta 3 1 Generator Set Start Test n A A a Gea 3 1 With Load Standby System Test n nunnana rd tae da ees 3 2 Overcrank Rest 3 Wire Start Only oocccccccccccccccrn teens 3 2 Planned MaintGnanCe 2 sais et O A AL ie a eee ee E da 3 3 Redistribution or publication of this document i by any means is strictly prohibited Table of Contents continued 4 TROUBLESHOOTING umi A ae ee ee eee es 4 1 Power Outage Occurs But the Generator Set Does Not Start 00000 4 1 Generators Starts Unexpected
19. cuit 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 generator set to stop Redistribution or publication of this document by any means is strictly prohibited Remote Test The transfer switch may be wired with a remote test switch Closure of a set of contacts across the re mote test input will initiate the transfer switch test mode During remote test a simulated utility power failure occurs and a start run signal is sent to the generator set If the Load No Load switch on the control circuit board is in the Load position Figure 2 2 the load is transferred to the generator set when generator set power becomes available If the Load No Load switch is in the No Load posi tion the generator set will start and run but it will not assume the load during the remote test THREE WIRE STARTING OPTION The optional three wire starting control enables the transfer switch to start and stop a three wire start generator set Three wire starting logic is similar to 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 an over crank relay a preheat relay two Timing Lamps a Lockout Lamp a Reset Switch an Auto Stop Hand crank Switch and a Preheat Timer On Off Switch Figure 2 3 Overcrank occurs when the
20. d more assistance please call Onan Corporation 1 612 574 5000 7 30 AM to 4 00 PM Central Standard Time Monday Friday When contacting your distributor always supply the complete Model Number and Serial Number as shown on the nameplate Redistribution or publication of this document by any means is strictly prohibited 2 Description GENERAL Automatic transfer switches control transfer of the load to the Normal power source or to the Emergen cy power source generator set without operator in volvement The RST transfer switch is available with one of two control package options Control package A has the standard feature set control package B has a high er level of features This section describes both control packages Cabinet The cabinet Figure 2 1 meets the requirements for a UL Type 1 cabinet This type is designated as a general purpose indoor cabinet Auto Manual Switch The Auto Manual switch located on the control cir cuit board Figure 2 2 is used to enable or disable the automatic retransfer function This switch has two positions In the Auto position normal automat ic retransfer is enabled In the Manual position au tomatic retransfer from a functioning generator set back to utility power is disabled only manual re transfer is possible In the event of generator set failure the control logic will ignore the Auto Manual switch and initiate re transfer to utility power Lo
21. e button down the minutes will increment in SEGMENTS INDICATE 15 minute intervals When the Start time is EXERCISE TIME reached press the set button On Mode is indicated Figure 2 7 OFF MODE Then increment the time with the plus but ton to the desired Stop time When the Stop time is reached press the set button Off Mode is indicated Figure 2 7 Example to exercise the genset one hour Set Start at 7 00 PM 19 00 Set Stop at 8 00 PM 20 00 Note that the exercise time is indicated by a band of segments illuminated around the outer ring of the clock from the start to the stop time Figure 2 7 To clear the program press the plus and set D buttons at the same time 4 Pressing the arrow gt button advances to the next day The program will be copied to the next day if the next day does not have an existing program To change or clear the program press the plus EA IKG ES nrc E and set buttons at the same time PERMANENT ON OFF MODE MBE Double check the program setting for each day Press the arrow gt button repeatedly until the clock mode is passed and the pro gram mode Pr is reached Carefully check each days program and clear any unwanted programs 5 When finished programming press the arrow gt button until the clock appears in the upper left corner of the display During the exercise p
22. e or buttons until the desired day is underlined NOTE If an exercise period is already set for the selected day the program and CL r will be displayed If you wish to delete the set program press the OK button 4 Press the OK button The starting time 0 00 is flashed see Figure 10 ON PROG NEW 2124 lt Purr ia LILI G 1234567 Gaede FIGURE 10 EXERCISE CLOCK MENU 5 Press the or buttons to set the starting time for the exercise See Figure 11 NOTE If you lightly press the or buttons the value changes in one minute incre ments If you press and hold the or buttons the value changes in ten min ute increments Redistribution or publicatio e by any means Pag Sot ON PROG NEW 24 A A ig ELI cu 1234567 epee FIGURE 11 SETTING THE EXERCISE STARTING TIME 6 Press the OK button The starting time is still displayed and OFF is now displayed in the up per right corner of the screen see Figure 12 Press the button to set the exercise stop time 0 PROG NEW 0 24 8 6 4234567 Dannes FIGURE 12 SETTING THE EXERCISE STOP TIME 7 Press the OK button Press the OK button again to save the exercise program NOTE If the Delete Program menu is dis played see Figure 13 CLr is dis played indicating that the exercise pro gram can be deleted by pressing the OK button 24 Fy 18 hla J 1234567 e T adios
23. e Auto Manual Switch Auto position e Operation Selector Switch engine control Remote position Two wire start only e Stop Auto Handcrank switch Auto position Three wire start only The generator set must also be set for automatic operation GENERATOR SET EXERCISE Run the generator for at least 30 minutes once each week with at least 50 percent load if possible If you do not have control package B with the exercis er clock the remote test input can be used to test the generator set each week The exerciser clock has programmable exercise periods that will exercise the generator set automat ically with or without load depending on the position of the Load No Load switch If the Normal power source has an interruption while the generator set is exercising without load the automatic transfer switch will transfer the load to the generator set 3 1 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 Load No Load selector switch on the control Figure 2 2 in the No Load posi tion The Load No Load selector switch must be in the No Load position 2 Close the cabinet door AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause seve
24. e charging current automat ically tapers to zero amperes or to steady state load on the battery Redistribution or publication of this document by any means is strictly prohibited The battery charger is rated for 2 amperes at 12 or 24 VDC and has an ammeter to indicate charging current and a fuse to protect the battery charger cir cuit BATTERY CHARGER 2 AMP 12 24 VOLT 2 rev FLOAT VOLTAGE ADJUSTMENT 2 AMP CHARGER FIGURE 1 2 BATTERY CHARGER OPTIONS Two aftermarket kits are available for RST Transfer Panels with control package A e 2 to 3 Wire Start Kit Enables the transfer panel to start and stop a three wire start generator set e Exerciser Clock Kit Starts and runs the genera tor set at programmable intervals for selected durations The only aftermarket kit that is available for RST Transfer Panels with control package B is the 2 to 3 Wire Start Kit These kits must be installed by trained and experi enced service personnel only Exerciser Clock Control Package A The exercise clock is optional on RST Transfer Pan els with control package A and is standard equip ment on RST Transfer Panels with control package B The exerciser clock kit is used to start and run the generator set at programmable intervals and for se lected durations Cummins is a registered trademark of Cummins Inc Onan is a registered trademark of Onan Corporation 1 2 For exerciser clock installation and pr
25. e load is retransferred to the Normal power source At the end of the delay the stop sig nal is sent to the generator set This time delay al lows the generator set to cool down at no load be fore stopping Undervoltage Sensing Control package A has undervoltage sensing for one phase of the Normal and Emergency sides with fixed pickup and dropout settings Control package B has three phase undervoltage sensing for the Normal side and single phase sensing of the Emer gency side Control package B also has adjustable pickup and dropout settings Refer to the Installa tion manual for adjustment procedures The voltage sensors for the Normal and Emergency side monitor source voltages for an undervoltage condition and generate signals which are sent to the time delays If for example an under voltage condition is sensed on the Normal source the volt age sensor sends a signal to the time delay that initi ates and controls the timing for generator set start and the transfer of load On control package A Pickup voltage is preset to 85 of Normal and Dropout is preset to 75 of Pickup On control package B Pickup is adjustable from 85 to 100 of Normal and Dropout is adjust able from 75 to 98 of Pickup 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 is more involved the two wire starting cir
26. ear 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 Open the cabinet door and check the Emer gency available indicator light on the electronic control circuit board Figure 2 2 If the light is On proceed to step 2 If the light is not On pro ceed to step 3 2 Check for open circuit between genset and transfer switch or have genset checked for low voltage AFTER POWER RETURNS THE TRANSFER SWITCH DOES NOT RETURN TO THE NORMAL POSITION 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 The retransfer time delay period may not have expired Open the cabinet door and check the Retransfer Timing lamp and the Normal Avail able lamp on the electronic control circuit board Figure 2 2 2 Check the Auto Manual switch on the control circuit board Figure 2 2 to make sure it is in the Auto position see description in Section 2 Stop the generator set with the genset Start Stop switch When the generator set stops the transfer switch should transfer load to the Nor mal power source if Normal power is accept able 6 Call your dealer or distributor Redistribution or publication of this document
27. eration selec tor switch on the generator set control panel should be set at Remote AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death Use extreme cau tion to avoid touching electrical contacts whenever the cabinet door is open 2 Three wire starting only The Auto Stop Handcrank switch on the 3 Wire Start module should be set at Auto 3 If presetn check the exerciser clock to see if it is in an exercise period When the exerciser clock is in an exercise period the On mode is indicated in the ellipse in the upper right corner of the display Figure 4 1 If the exercise clock is not in the On mode check the programming in Section 2 Start the generator set using its start stop con trols If it does not crank check the starting bat teries If it cranks but does not start check the fuel supply If the problem persists call your dealer or distributor Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any arc spark or flame while servicing batteries Ignition of fuel can cause se vere personal injury or death by fire or ex plosion Do not permit any flame cigarette spark pilot light arcing equipment or oth er possible source of ignition near the fuel system 4 2 AFTER A POWER FAILURE THE GENERATOR SET STARTS BUT DOES NOT ASSUME LOAD AC power within the cabinet and the r
28. eriod the ON mode is indi cated in the ellipse in the upper right corner of the display Figure 2 7 To Check the Programs Push the arrow button to review each setting To Erase Clear a Program Press the arrow button until the program mode Pr is reached Press the arrow button again to select the desired day To clear the program for the day selected press the plus and set buttons FIGURE 2 7 EXERCISER CLOCK ON OFF MODE at the same time Redistribution or publication of this document 2 7 by any means is strictly prohibited To Initiate or Override an Exercise Program The exerciser clock has a built in test feature Once the clock time has been set the set button DB can be used to initiate a test or to cancel a test in prog ress The Load No Load switch on the control circuit board Figure 2 2 can be set to test the genset with or without load as desired With the normal source connected and available pressing the set button once will initiate a test sequence A hand will be displayed in the upper left corner of the display and the On mode will be indi cated inside the ellipse in upper right corner of the display Figure 2 7 Pressing the set button again will stop the test and the ellipse will indicate the OFF mode To temporarily override an activated exercise pro gram momentarily press the set button A small 2 8 hand will appe
29. hangeover No changeover North America OK button Use the and buttons to set the actual day and month of real time and then press the OK Freely programmable date with regards to the change from summer to winter time Northern Hemisphere Use the and buttons to put in the date at which the summer time starts and ends at your location in your country The weekday is automatically allocated to the date Southern Hemisphere For the southern hemisphere the date at which the summer time starts ends must be programmed for the same year Use the and buttons to set the year and then press the OK button Use the and buttons to set the actual day and month of summer time and then press the button To set exercise start and stop times NOTE The start and stop time for an exercise peri od must both be in the same day For exam ple you cannot have a 30 minute exercise period start at 23 45 on one day and stop at 0 15 on the following day 1 Press the MENU button The selector button Ca will pointing at PROG Press the OK button 2 The selector button will be pointing at PROG NEW Press the OK button again ON is dis played in the top right corner of the screen and the first day of the week is underlined see Fig ure 9 ON PROG NEW E 24 18 6 1284567 12 FIGURE 9 SETTING THE DAY OF THE WEEK THE EXERCISE IS TO BEGIN 3 To select a different day press th
30. ly During Normal Power Service 000 0005 4 1 Generator Set Does Not Exercise 0 ccc een ene teen ene nnes 4 2 After a Power Failure the Generator Set Starts But Does Not Assume Load 4 2 After Power Returns the Transfer Switch Does Not Return to the Normal Position 4 2 Generator Set Continues to Run After Retransfer of Load to Normal Power 4 3 Battery Charger Fails to Charge If Equipped ococococcccccccncccc 4 3 Battery Loses Water 00 ccc ttn tenn t eee n eens 4 3 Battery Loses Charges iras rior teria eee ses tees erario tula 4 3 AWARNING INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH SEVERE PERSONAL INJURY AND OR EQUIPMENT DAMAGE SER VICE PERSONNEL MUST BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND OR MECHANICAL SERVICE Redistribution or publication of this document ji by any means is strictly prohibited Safety Precautions This manual includes the following symbols to indi cate potentially dangerous conditions Read the manual carefully and know when these conditions exist Then take the necessary steps to protect 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 per
31. m hardware for loose connections Tighten as indicated in step 4 Check all control wiring and power cables especially wiring between or near hinged door for signs of wear or deterioration Check all control wiring and power cables for loose connections Tighten as indicated in step 4 Check the 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 the Service Manual 913 0505 Retorque all cable lug connections Lug torque requirements are listed in Section 1 of the Service Manual b Service or replace the batteries 5 CONNECT AC POWER AND CHECK OPERATION a 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 Redistribution or publication of this document 3 3 by any means is strictly prohibited THIS PAGE LEFT INTENTIONALLY BLANK Redistribution or publication of this document 3 4 by any means is strictly prohibited 4 Troubleshooting The following procedures describe preliminary trou bleshooting checks These checks should only be performed by someone familiar with troublesh
32. mal power source The automatic transfer and retransfer of the load are the two basic functions of a transfer panel AUTOMATIC TRANSFER PANELS Automatic transfer panels capable of automatic op eration without operator involvement perform the following basic functions 1 Sense the interruption of the Normal power source 2 Send a 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 RST Automatic Transfer Panel is a trademark of Onan Corporation 1 1 5 Retransfer the load to the Normal power source 6 Send a stop signal to the generator set NORMAL EMERGENCY FIGURE 1 1 LOAD TRANSFER PANEL TYPICAL FUNCTION 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 If it is necessary to contact a dealer or distributor re garding the transfer panel always give the com plete Model Specification and Serial number This information is necessary to properly identify your unit among the many types being manufactured FLOAT BATTERY CHARGER A float charge battery charger Figure 1 2 regu lates its charge voltage to continuously charge with out damage to the battery As the battery ap proaches full charge th
33. ogramming changes please contact your authorized Cummins Onan dealer Three Wire Start An optional three wire starting control kit enables the transfer panel to start and stop a three wire start generator set Three wire starting logic is similar to 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 an over crank relay a preheat relay two Timing Lamps a Lockout Lamp a Reset Switch an Auto Stop Hand crank Switch and a Preheat Timer On Off Switch HOW TO OBTAIN SERVICE When the transfer panel requires servicing contact your nearest dealer or distributor Factory trained Parts and Service representatives are ready to han dle all your service needs If unable to locate a dealer or distributor consult the Yellow Pages Typically our distributors are listed under GENERATORS ELECTRIC ENGINES GASOLINE OR DIESEL OR RECREATIONAL VEHICLES EQUIPMENT PARTS AND SERVICE For the name of your local Cummins Onan or Onan only distributor in the United States or Cana da call 1 800 888 ONAN This automated service utilizes touch tone phones only By entering your area code and the first three digits of your local tele phone number you will receive the name and tele phone number of the distributor nearest you For the name of your local Cummins only distribu tor or if you nee
34. ogramming the exerciser clock requires setting the time of day and entering the exercise start and stop times as described in the following sections The exerciser clock has backup power for approxi mately six hours After six hours the day and time will have to be reset Exercise programs will not be lost during a power outage exercise programs are stored in EEPROM To Reset the Exerciser Clock Resetting the exerciser clock erases all exist ing day time and exercise program settings Depress and hold the arrow plus and set but tons DB simultaneously Release the plus and arrow buttons while continuing to hold the arrow button When all aspects of the LCD display appear release the arrow button To Set the Day and Time 1 With the exerciser clock powered press all three buttons simultaneously to reset the time The time display area will show and a small clock symbol will appear in the upper left corner of the display Refer to Figure 2 6 2 Press the arrow button once to set the day of week The clock symbol will begin flashing to indicate the clock is being programmed and the display will show midnight 0 00 3 Press the plus button as many times as nec essary until the current day of week is dis played Example 1 Monday 2 Tuesday etc 4 Press the arrow gt button again to set the hour of the day The clock uses 24 hour mili tary time 5 Press the plus bu
35. oot ing electrical equipment Observe all safety precau tions If the trouble persists call your dealer or dis tributor POWER OUTAGE OCCURS BUT THE GENERATOR SET DOES NOT START 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 If the transfer switch has the 3 Wire Start mod ule the Auto Stop Handcrank switch on the 3 Wire Start module should be set to Auto Check for overcrank condition See Operation Section 2 If the transfer switch has two wire starting check the generator set The operation selec tor switch on the generator set control panel should be set at Remote Check for fault indica tors on the generator set control 3 Start the generator set using its start stop con trols If it does not crank check the starting bat teries If it cranks but does not start check the fuel supply If the problem persists call your dealer or distributor Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any arc spark or flame while servicing batteries Ignition of fuel can cause se vere personal injury or death by fire or ex plosion Do not permit any flame cigarette spark pilot light arcing equipment electri cal switch or other possible source of igni tion near the fuel system 4
36. re personal injury or death Close the cabinet door 3 Activate the remote test input The generator set should start and run At the end of the test period deactivate the re mote test input The generator will stop 4 In anticipation of scheduled or automatic gen erator set exercise check that the Load No Load selector switch is in the desired position Figure 2 2 Refer to Generator Set Exercise Close and lock the cabinet door Redistribution or publication of this document by any means is strictly prohibited WITH LOAD STANDBY SYSTEM 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 Load No Load selector switch on the control circuit board in the Load position The Load No Load selector switch must be in the Load position in order to test with load 2 Close the cabinet door AC power within the cabinet and the rear side of the cabinet door pres ents a shock hazard that can cause severe personal injury or death Close the cabinet door 3 2 3 Activate the remote test input The generator set should start and assume the load after the start and transfer time delays At the end of the test period deactivate the re mote test input The generator will stop after the retransfer and stop time delays OV
37. ributor Redistribution or publication of this document by any means is strictly prohibited THIS PAGE LEFT INTENTIONALLY BLANK Redistribution or publication of this document 4 4 by any means is strictly prohibited Cummins Power Generation 1400 73rd Avenue N E Minneapolis MN 55432 1 800 888 6626 763 574 5000 International Use Power Fax 763 528 7229 Generation Cummins is a registered trademark of Cummins Inc Redistribution or publication of this document by any means is strictly prohibited
38. safe Redistribution or publication of this document by any means is strictly prohibited THIS PAGE LEFT INTENTIONALLY BLANK Redistribution or publication of this document iv by any means is strict R8dHbited 1 Introduction The RST Automatic Transfer Panel is completely automatic and requires no operator involvement Keep the transfer panel door securely closed at all times and make sure only qualified service person nel have access to the cabinet The following section describes the basic automatic transfer switch operation High voltage inside the transfer panel presents serious shock hazards that can result in severe personal injury or death Ser vice and adjustments must only be performed by an electrician or authorized service person nel TRANSFER PANEL APPLICATION Transfer panels are an essential part of a building s standby or emergency power system The Normal power source commonly the utility line is backed up by an Emergency power source often an electric generating set The transfer panel supplies the electrical load with power from either of these two power sources The load is connected to the common of the transfer panel Figure 1 1 Under normal conditions the load is supplied with power from the Normal source as illustrated When the Normal power source is interrupted the load is transferred to the Emergen cy power source When Normal power returns the load is retransferred to the Nor
39. set operation selector switch to Stop disconnect AC line power disconnect the battery charger from its AC power source and discon nect the starting battery negative lead first before servicing Ignition of explosive battery gases can cause severe personal injury Do not smoke or cause any spark arc or flame while servicing batteries TABLE 3 1 ANNUAL PREVENTIVE MAINTENANCE 1 BEFORE SERVICING DISCONNECT ALL SOURCES OF AC POWER a Disconnect both AC power sources from the transfer switch before continuing Turn the genera tor set operation selector switch to Stop The selector switch is located on the generator set con trol panel b If there is an external battery charger disconnect it from its AC power source c Then disconnect the set starting battery negative lead first 2 CLEAN a Thoroughly dust and vacuum all controls switching mechanism components interior buswork and connecting lugs b Close the cabinet door and wash exterior surfaces with a damp sponge mild detergent and wa ter Do not allow water to enter the cabinet especially at lamps and switches 3 INSPECT Check buswork and supporting hardware for carbon tracking cracks corrosion or any other types of deterioration If replacement is necessary call your dealer or distributor Check stationary and movable contacts If contact replacement is necessary the procedures are described in Section 4 of the Service Manual 913 0505 Check syste
40. settings are adjustable on control package B Refer to the Installation manual for adjustment procedures Start Time Delay This delay is preset to 3 seconds on control package A and is adjustable from 0 5 to 15 seconds on control package B This brief time delay prevents generator set starting during power interruptions of short duration Timing starts the mo ment of Normal utility power interruption If the duration of interruption exceeds the delay time the control system signals the generator set to start Transfer Time Delay This delay timing 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 set to stabilize before the load is applied The time is preset to 3 seconds on control package A and is ad justable from 2 to 120 seconds on control package B 2 3 Retransfer Time Delay This delay begins the mo ment Normal line voltage returns After the delay the transfer switch can retransfer the load to the Normal source The delay allows the Normal source to stabilize before retransfer The time is preset to 5 minutes on control package A and it is adjustable from 6 seconds to 30 minutes on control package B Stop Time Delay This delay is preset to 5 minutes on control package A and is adjustable from 2 sec onds to 10 minutes on control package B It begins timing when th
41. sonal inju ry or product or property damage High voltage in transfer panel components pres ents serious shock hazards that can result in severe personal injury or death Read and follow these suggestions Keep the transfer panel cabinet closed and locked Make sure only authorized service personnel have access to the cabinet Due to the serious shock hazard from high voltages within the cabinet all service and adjustments to the transfer panel must be performed only by an electrician or authorized service personnel Instructions to Authorized Service Personnel If the cabinet must be opened for any reason 1 Move the operation selector switch on the gen erator set to OFF If the transfer panel is equipped with the 3 Wire Start Option move the toggle switch to the Stop position 2 Remove the AC power source to the cabinet 3 Disconnect the starting batteries of the genera tor set remove the ground lead first Place rubber insulative mats on dry wood platforms over metal or concrete floors when working on any electrical equipment Do not wear damp clothing particularly wet shoes or allow skin surfaces to be damp when handling any electrical equipment Jewelry is a good conductor of electricity and should be removed when working on the electrical equipment Do not work on this equipment when mentally or physically fatigued or after consuming alcohol or any drug that makes the operation of equipment un
42. tton until the current hour is displayed Example 2 00 PM is 14 00 2 6 6 Press the arrow gt button again to set the minutes 7 Press the plus button until the current min utes are displayed Note that by holding the plus button down the minutes will increment in 5 minute intervals 8 To set or change the exercise program press the arrow button again and go to step two in the following section To return to the normal operating mode press the arrow gt button eight times clock symbol appears in the dis play Pr INDICATES PROGRAMMING MODE CLOCK SYMBOL TIME DISPLAY DAY DISPLAY FIGURE 2 6 EXERCISER CLOCK To Set the Exercise Start and Stop Time 1 Press the arrow gt button four times to start the programming mode 2 The letters Pr will appear in the lower right hand corner of the display when the programing mode is reached Pr will be flashing if there are no existing programs Press the arrow gt button as many times as necessary to advance to the day to be pro grammed To clear an existing program for the day se lected press the plus and set buttons at the same time Redistribution or publication of this document by any means is strictly prohibited 3 Press the plus button to increment the Start time of the exercise program The display will show midnight 0 00 Note that by holding th
43. tton until the home menu is redisplayed Permanent On Off Mode The Permanent On Off Manual Override mode re verses the set exercise state It is initiated by using the selector button to select the Manual Override mode see Figure 18 The exercise state indica tor shown in the bottom right corner of the display will then be reversed aunt FIGURE 18 SELECTING PERMANENT ON OFF MODE To exit the Permanent On Off mode press the selec tor button Ca until the Automatic Operation mode is selected The exercise state indicator shown in the bottom right corner of the display will go back to its normal state Redistribution or publicatio e by any means Pag ook ent ited To initiate or override exercise program s The exerciser clock has a built in test feature Once the clock time has been set the selector button Ca can be used to select Continuous Override ON mode O to initiate a test see Figure 19 or select Continuous Override OFF mode O to cancel a test in progress see Figure 20 2 24 J 6 1294567 8 02 19 O anno FIGURE 19 CONTINUOUS OVERRIDE ON CN E ig Bett 6 s 1234567 Fy A N 12 O anat FIGURE 20 CONTINUOUS OVERRIDE OFF Page 8 of 8 To exit either mode press the selector button Ca un til Automatic Operation mode is selected The ex ercise state indicator shown in the bottom right cor ner of the display will go back to its normal state
Download Pdf Manuals
Related Search