This is the Highly Detailed factory service repair manual for theCUMMINS ONAN BTPCD TRANSFER SWITCH 150-1000 AMPERES, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. They are specifically written for the do-it-yourself-er as well as the experienced mechanic.CUMMINS ONAN BTPCD TRANSFER SWITCH 150-1000 AMPERES Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly. Service Repair Manual Covers: Introduction Description Operation Digital Display Menu System Events Troubleshooting Automatic Transfer Switch Service Bypass Switch Service Protective Relay Schematics File Format: PDF Compatible: All Versions of Windows & Mac Language: English Requirements: Adobe PDF Reader NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise!
All pages are is great to haveCUMMINS ONAN BTPCD TRANSFER SWITCH 150-1000 AMPERES Service Repair Workshop Manual. Looking for some other Service Repair Manual,please check: Thanks for visiting! CUMMINS ONAN BTPCD TRANSFER SWITCH 150-1000 AMPERES Service Repair Manual. 1. Service Manual Transfer Switch BTPCB (Spec A) BTPCC (Spec A−B) BTPCD (Spec A) 150−1000 Amperes English 10−2009 962−0518 (Issue 6). i Table of Contents SECTION TITLE PAGE SAFETY PRECAUTIONS ix. INTRODUCTION 1-1.
Selecting the correct automatic transfer switch is crucial to completing a. 100, 150, 225, 260, 400, 600, 800, 1000, 1200, 1600, 2000, 3000 and 4000 amperes.
About This Manual 1-1. Transfer Switch Application 1-1. Bypass Switch Function 1-2. Drawout Isolation Mechanism 1-2. Utility-to-Genset Operation 1-2.
Utility-to-Utility Operation 1-2. Removing and Replacing Electronic Control Components 1-2. Model Identification 1-3. How to Obtain Service 1-3.
DESCRIPTION 2-1. Cabinet 2-1. Control Panel 2-1. Bar Graph Meter Panel 2-2. AC Ammeter (A−) 2-2. Power Meter (kW) 2-2. Power Factor Meter (PF) 2-2.
Frequency Meter (Hz) 2-2. AC Voltmeter (V−) 2-2. Switch Panel 2-2. Indicator Lamps 2-2.
Source 1 Available and Source 2 Available 2-2. Source 1 Connected 2-2. Source 2 Connected 2-2.
Not in Auto 2-2. Test/Exercise Active 2-2. Membrane Pushbuttons 2-3. Test 2-3. Override 2-3.
Reset/Lamp Test 2-3. Digital Display 2-3. Security Key Switch Option 2-3. Bypass Switch 2-6. Contact Assemblies 2-6. Auxiliary Contacts 2-6.
Bypass Switch Controls 2-6. Indicators 2-6.
Bypass Handle and Select Switch 2-7. ii SECTION TITLE PAGE Drawout-Isolation Mechanism 2-7.
Drawout Cranking Handle 2-7. Automatic Transfer Switch 2-8. Contact Assemblies 2-8.
Linear Actuator 2-8. Auxiliary Switches 2-8. Motor Disconnect 2-8. Electronic Control System 2-9. Electronic Control Circuit Modules 2-9.
Digital Module 2-9. Power Module 2-10. Single Linear Motor (Open Transition): 2-11. Dual Linear Motor (Closed Transition): 2-11. Two-Wire Starting 2-11. Electronic Control Options 2-11. Relay Module Option 2-11.
Load Monitoring 2-13. Remote Test Transfer 2-13. Auxiliary Relays 2-13. Battery Charger Options 2-14.
Original Float Battery Chargers 2-14. Current Float Battery Chargers 2-15. 2-Amp Battery Charger 2-15. 15/12-Amp Battery Charger 2-16. Load Shed 2-18.
PowerCommand Network Interface 2-18. OPERATION 3-1. Functional Programs 3-1.
Transition Modes 3-1. Open Transition with Sync Check 3-1. Programmed Transition 3-1. Closed Transition 3-1. Time Delays 3-1. Time Delay Engine Start (TDESa) 3-2. Time Delay Engine Cooldown (TDECa) 3-2.
Time Delay Normal to Emergency (TDNE) 3-2. Time Delay Emergency to Normal (TDEN) 3-3.
Programmed Transition Time Delay (TDPT) 3-3. Elevator Time Delay (TDEL) 3-3.
Average Transfer Time(s) 3-3. System Sensors 3-4. Undervoltage Sensors 3-4. Overvoltage Sensors 3-5. Frequency Sensors 3-6. Voltage Imbalance Sensor 3-7.
iii SECTION TITLE PAGE Phase Rotation Sensor 3-7. Loss of Single Phase Sensor 3-8. Sync Check Sensor 3-8. Active Sync Feature 3-9.
Speed Adjust 3-9. Generator Tests, Exercises, and Exercise Exceptions 3-10. Testing With or Without Load 3-10. Generator Set Start Test Without Load 3-10. Generator Set Start Test With Load 3-10. Real-Time Clock 3-10. Sleep Mode 3-11.
Programmable Generator Set Exercises 3-12. Setting Exercise(s) − For Software Versions Prior to 1.5.190 3-12.
Setting Exercise(s) − Starting with Software Version 1.5.190 3-14. Setting Exercise Exception(s) − Starting with Software Version 1.5.190 3-15. Setting Exercise(s) − Starting with Software Version 1.13.244 3-16. Setting Exercise Exception(s) − Starting with Software Version 1.13.244 3-17 Events 3-18.
Automatic Operation 3-18. Bypassing the Transfer Switch 3-19. Bypassing Load to Normal (Source 1) 3-19. Bypassing Load to Emergency (Source 2) 3-19. Isolating the Transfer Switch 3-19. Reconnecting the Transfer Switch 3-20.
Load is Bypassed to the Normal Source 3-20. System Testing 3-21.
Generator Set Start Test 3-21. With Load Standby Test 3-21. Non-Load Break Transfer Switch Test 3-22. Transfer Switch Maintenance 3-23.
Power System Functional Tests 3-23. Weekly Inspection 3-23.
Monthly Testing 3-23. Annual Maintenance and Testing 3-23. Clean and Inspect the Switch 3-23. Annual Testing 3-24. Thermography 3-24. DIGITAL DISPLAY MENU SYSTEM 4-1. Main Menus 4-1.
Setup Menus 4-1. Navigation 4-1.
Main Menu Navigation 4-2. Using the Previous Menu Button 4-2. Main Menu Descriptions 4-3.
Source 1 and Source 2 Submenus 4-4. iv SECTION TITLE PAGE Load Submenus 4-5. Statistics Submenus 4-6. Prior to Software Version 1.12 4-6. Starting with Software Version 1.12 4-7. Events Submenus 4-8.
Setup Submenus 4-9. Setup Menu Navigation and Description 4-10. Changing Setup Parameters 4-11.
Software Versions Prior to Version 1.12 4-11. Starting with Software Version 1.12 4-12. Sensor 1 & Sensor 2 Submenus 4-13.
Software Versions Prior to Version 1.12 4-13. Starting with Software Version 1.12 4-15. Sync Check Submenus 4-17.
Time Delay Submenus 4-18. Software Versions Prior to Version 1.12 4-18. Starting with Software Version 1.12 4-19. Test Submenus 4-20.
Exerciser Submenus 4-21. Software Versions Prior to 1.5.190 4-21. Starting with Software Version 1.5.190 4-23. Exercise Exceptions Submenus 4-25. Starting with Software Version 1.5.190 4-25. Starting with Software Version 1.12 4-27. Starting with Software Version 1.12 4-29.
Starting with Software Version 1.13.244 4-31. Starting with Software Version 1.13.244 4-33. Mode Submenu 4-35. Prior to Software Version 1.20.250 4-35. Starting with Software Version 1.20.250 4-35.
Clock Submenus 4-36. Sequencer Submenus 4-37. About Submenus 4-38. Prior to Software Version 1.20.250 4-38. Starting with Software Version 1.20.250 4-40. System Submenus 4-42.
Active TD Submenus 4-43. Prior to Software Version 1.12 4-43. Starting with Software Version 1.12 4-44. Introduction 5-1. Event History 5-1.
Events 5-1. ATS Common Alarm 5-1. Battery Charger Fault 5-1. v SECTION TITLE PAGE Common Alarm A 5-1. Common Alarm B 5-1.
Control Battery Low 5-1. Emergency Start A 5-2.
Exercise Active 5-2. Fail to Sync 5-2.
Fail to Disconnect 5-2. Fail to Retransfer 5-2. Fail to Transfer 5-3. High Neutral Amps 5-3. Load Shed 5-3. Motor Disconnect 5-3.
Network Battery Low 5-3. Network Error 5-3. Network Wink 5-3. Not in Auto 5-3. Panel Lock Switch 5-3. Phase Rotation Fail 5-4. Retransfer Inhibit 5-4.
S1 Failed to Close 5-4. S1 Failed to Open 5-4. S1 Frequency Fail 5-4. S1 Imbalance Fail 5-4. S1 Loss Phase 5-4. S1 Over Voltage 5-4.
S1 Under Voltage 5-4. S2 Failed to Close 5-4.
S2 Failed to Open 5-4. S2 Frequency Fail 5-4.
S2 Imbalance Fail 5-4. S2 Loss Phase 5-5. S2 Over Voltage 5-5. S2 Stopped 5-5. S2 Under Voltage 5-5. Sequencer Output 1 thru Sequencer Output 8 5-5. Service Tool 5-5.
Source-1 Available 5-5. Source-1 Connected 5-5. Source-2 Available 5-5.
Source-2 Connected 5-5. Speed Adjust 5-5. Sync Check Active 5-6. Sync Enable 5-6. TDECa (Time Delay Engine Cool-Down (A)) 5-6. TDEL (Transfer Pending) 5-6.
TDEN (Time Delay Source 2 (E) to Source 1 (N)) 5-6. vi SECTION TITLE PAGE TDESa (Time Delay Engine Start A) 5-6.
TDNE (Time Delay Source 1 (N) to Source 2 (E)) 5-6. TDPT (Time Delay Programmed Transition) 5-7. Test In Progress 5-7. Test Start A 5-7. Transfer Inhibit 5-7. TROUBLESHOOTING 6-1.
InPower Service Tool 6-1. About Network Applications and Customer Inputs 6-1. Digital Module 6-2. Power Module 6-2. Control LED Indicators and Switch 6-2. LED Indicators 6-2. Exerciser Enable/Disable Switch 6-2.
Sequence of Events 6-3. Transfer from Source 1 to Source 2 6-3. Transfer from Source 2 to Source 1 6-4.
Troubleshooting Using Fault Codes 6-5. Fault Events 6-5.
Fault Flash-Out 6-5. Fault Event Definitions 6-8. Controller Checksum Error 6-8. Low Controller Battery 6-8. ATS Fail to Close: Transfer 6-8.
ATS Fail to Close: Re-Transfer 6-8. Battery Charger Malfunction 6-8. Network Battery Low 6-8. Network Communications Error 6-8. Troubleshooting with Symptoms 6-9. Troubleshooting Warnings 6-9. AUTOMATIC TRANSFER SWITCH SERVICE 7-1.
General 7-1. Membrane Switch Test 7-1.
Power Module Test 7-2. Digital Board Replacement 7-3. Initial Calibration 7-3. Setup with a Capture File 7-3.
Setup Without a Capture File 7-3. After the Setup is Completed 7-3. Removing the Automatic Transfer Switch 7-6. Bypass and Isolate the Transfer Switch 7-6. Remove the Transfer Switch 7-6. Installing the Automatic Transfer Switch (When Finished) 7-7.
Reconnecting the Transfer Switch 7-7. vii SECTION TITLE PAGE Linear Actuator Removal and Replacement (150-225-260 Amperes) 7-8. Removing Actuator 7-8. Replacing Actuator 7-8.
Block and Cross-Bar Assembly Removal and Replacement (150-225-260 Amperes) 7-11 Removing the Block and Cross-Bar Assembly (Normal or Emergency) 7-11. Replacing Block and Cross-Bar Assembly (Normal or Emergency) 7-14. Auxiliary Switch Removal and Replacement (150-225-260 Amperes) 7-15. Removing Auxiliary Switch Assembly 7-15. Replacing Auxiliary Switch Assembly 7-15. Linear Actuator Removal and Replacement (300-400 Amperes Spec A and 300−600 Amperes Spec B) 7-16.
Removing Actuator 7-16. Replacing Actuator 7-16.
Block and Cross-Bar Assembly Removal and Replacement (300-400 Amperes Spec A and 300-600 Amperes Spec B) 7-19. Removing the Block and Cross-Bar Assembly (Normal or Emergency) 7-19. Replacing Block and Cross-Bar Assembly (Normal or Emergency) 7-22. Auxiliary Switch Removal and Replacement (300−400 Amperes Spec A and 300−600 Amperes Spec B) 7-23. Removing Auxiliary Switch Assembly 7-23. Replacing Auxiliary Switch Assembly 7-23.
Linear Actuator Removal and Replacement (600-800-1000 Amperes Spec A) 7-24. Removing Actuator 7-24. Replacing Actuator 7-24. Block and Cross-Bar Assembly Removal and Replacement (600-800-1000 Amperes Spec A) 7-27.
Removing the Block and Cross-Bar Assembly (Normal or Emergency) 7-27. Replacing Block and Cross-Bar Assembly (Normal or Emergency) 7-30. Auxiliary Switch Removal and Replacement (600-800-1000 Amperes Spec A) 7-31 Removing Auxiliary Switch Assembly 7-31. Replacing Auxiliary Switch Assembly 7-31.
Mis-Wired Current Transformers 7-32. BYPASS SWITCH SERVICE 8-1. Bypass, Isolation, and Removal Procedure 8-1. Remove the Transfer Switch 8-1. Disconnect AC Power 8-1.
Reconnect AC Power and Install and Reconnect the Automatic Transfer Switch. 8-1 Installing the Automatic Transfer Switch (When Finished) 8-2.
Reconnecting the Transfer Switch 8-2. Block and Cross-Bar Assembly Removal and Replacement (150-225-260 Amperes) 8-2 Removing the Block and Cross-Bar Assembly (Normal or Emergency) 8-3.
Replacing Block and Cross-Bar Assembly (Normal or Emergency) 8-7. Auxiliary Switch Removal and Replacement (150-225-260 Amperes) 8-8. viii SECTION TITLE PAGE Removing Auxiliary Switch Assembly 8-8.
Replacing Auxiliary Switch Assembly 8-9. Block and Cross-Bar Assembly Removal and Replacement (300-400 Amperes Spec A and 300-600 Amperes Spec B) 8-10. Removing the Block and Cross-bar Assembly (Normal or Emergency) 8-10. Replacing the Block and Cross-bar Assembly (Normal or Emergency) 8-14.
Auxiliary Switch Removal and Replacement (300-400 Amperes Spec A and 300-600 Amperes Spec B) 8-15. Removing Auxiliary Switch Assembly 8-15. Replacing Auxiliary Switch Assembly 8-16.
Block and Cross-Bar Assembly Removal and Replacement (600-800-1000 Amperes Spec A) 8-16. Removing the Block and Cross-bar Assembly (Normal or Emergency) 8-17. Replacing the Block and Cross-bar Assembly (Normal or Emergency) 8-22. Auxiliary Switch Removal and Replacement (600-800-1000 Amperes Spec A) 8-23 Removing Auxiliary Switch Assembly 8-23.
Replacing Auxiliary Switch Assembly 8-24. PROTECTIVE RELAY 9-1.
10.SCHEMATICS 10-5. Schematic PAG E 10-5. POWER MODULE (PIN-OUTS) 10-6.
POWER MODULE AC POWER CONNECTIONS (PIN-OUTS) 10-6. DIGITAL MODULE (PIN-OUTS) 10-7. Typical Interconnection Diagram (Sheet 1 of 10) 10-9. Typical Interconnection Diagram (Sheet 2 of 10) 10-10. Typical Interconnection Diagram (Sheet 3 of 10) 10-11. Typical Interconnection Diagram (Sheet 4 of 10) 10-12. Typical Interconnection Diagram (Sheet 5 of 10) 10-13.
Typical Interconnection Diagram (Sheet 6 of 10) 10-14. Typical Interconnection Diagram (Sheet 7 of 10) 10-15. Typical Interconnection Diagram (Sheet 8 of 10) 10-16.
Typical Interconnection Diagram (Sheet 9 of 10) 10-17. Typical Interconnection Diagram (Sheet 10 of 10) 10-18. Typical Wiring Diagram (Sheet 1 of 5) 10-19. Typical Wiring Diagram (Sheet 2 of 5) 10-20. Typical Wiring Diagram (Sheet 3 of 5) 10-21.
Typical Wiring Diagram (Sheet 4 of 5) 10-22. Typical Wiring Diagram (Sheet 5 of 5) 10-23. 125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 1 of 5) 10-24. ix SECTION TITLE PAGE 125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 2 of 5) 10-25. 125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 3 of 5) 10-26. 125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 4 of 5) 10-27. 125−1000 Amp Dual Linear Motor Typical Wiring Diagram (Sheet 5 of 5) 10-28.
Power Module 2 Assembly 10-29. Typical Interconnect Diagram − Genset to Genset, Plant to Plant 10-30.
Typical Interconnect Diagram − Genset to Genset, Dual Stand-By System 10-31. M045 − Protective RElay 10-32. M045 PROTECTIVE RELAY 10-33. M046/M047 − Protective RELAY 10-34.
M046/M047 PROTECTIVE RELAY 10-35. M046/M047 − Protective RELAY 10-36. M046/M047 PROTECTIVE RELAY 10-37.
x 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. DANGER This symbol warns of immediate hazards that will result in severe personal inju- ry or death. WARNING This symbol refers to a hazard or unsafe practice that can result in severe per- sonal injury or death.
CAUTION This symbol refers to a hazard or unsafe practice that can result in personal inju- ry or product or property damage. ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH High voltage in transfer switch components pres- ents serious shock hazards that can result in 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 an electrician or authorized service representative.
Whenever the bypass switch is in the Emergency position, an auxiliary switch closes a set of normally open contacts to provide a constant generator set start/run signal. The transfer switch, the emer- gency bus, and the load bus are energized by the output of the generator set and present a serious shock hazard whenever the bypass switch is in the Emergency position. UTILITY-TO-GENSET OR GENSET-TO- GENSET APPLICATIONS If the cabinet must be opened for any reason: 1. Move the operation selector switch on the gen- erator set to Stop. Disconnect the battery charger. Disconnect the starting batteries of the gener- ator set or sets (remove the ground − lead first). Remove AC power to the automatic transfer switch.
If the instructions require otherwise, use extreme caution due to the danger of shock hazard. UTILITY-TO-UTILITY APPLICATIONS If the cabinet must be opened for any reason, re- move AC power to the automatic transfer switch. If the instructions require otherwise, use extreme caution due to the danger of shock hazard.
GENERAL PRECAUTIONS Place rubber insulative mats on dry wood platforms over metal or concrete floors when working on any electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surfaces to be damp when handling any electrical equipment. Jewelry is a good conductor of electricity and should be removed when working on the electrical equipment. Wear safety glasses whenever servicing the trans- fer switch and and do not smoke near the batteries. Do not work on this equipment when mentally or physically fatigued, or after consuming alcohol or any drug that makes the operation of equipment unsafe. WARNING INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN DEATH, SEVERE PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE TRAINED AND EXPERIENCED TO PERFORM ELECTRICAL AND/OR MECHANICAL SER- VICE.
BTPC-2. xi This Page Intentionally Left Blank. 1-1 1.
Introduction ABOUT THIS MANUAL This manual contains service procedures for By- pass Transfer Switch PowerCommandR (BTPC) automatic transfer switches (ATS) rated at 150−1000 amperes and 300−600 amperes. This manual provides information on the following transfer switch models. BTPC transfer switches are open transition trans- fer switches. With an open transition switch there is never a time when both sources are supplying power to the load. BTPC transfer switches are ca- pable of executing Open Transition with Sync Check, Programmed Transition, and Closed Tran- sition transfer modes. An Open Transition with Sync Check Transfer Mode executes an open transition when both sources of power are within specified tolerances of frequency, voltage, and relative phase difference. If both sources meet the tolerances, a fast transfer occurs.
A Programmed Transition Transfer Mode exe- cutes an open transition by disconnecting the load from the source of power, pausing in the neutral position of the transfer switch (between switched positions) to allow transient currents from the load to diminish, and then the load is switched to the other source. A Closed Transition Transfer Mode executes a load transfer by momentarily paralleling both sources (a maximum of 100ms) before switching sources.
Refer to the schematic and wiring diagram pack- age that was shipped with the ATS for specific in- formation about its configuration. Use normal and necessary safety precautions be- fore starting any service procedure. Identify all hazards by referring to the Safety Precautions and observe all warnings and cautions within the manual. Whenever you are troubleshooting, re- member that the generator set, ATS, and utility power source are all interdependent.
TRANSFER SWITCH APPLICATION The BTPC transfer switch combines an automatic transfer switch, a manual bypass switch and a drawout isolation mechanism in one unit. Transfer switches are an essential part of a build- ing’s standby or emergency power system. Power Source 1 (Normal), commonly the utility line, is backed up by Power Source 2 (Emergency), often a generator set. The transfer switch automatically switches the electrical load from one source to the other.
The load is connected to the common of the ATS (Figure 1-1). Under normal conditions, the load is supplied with power from Source 1 (illustrated as Normal). If Source 1 is interrupted, the load is transferred to Source 2 (Emergency). When Source 1 returns, the load is retransferred to Source 1. The transfer and retransfer of the load are the two most basic functions of the ATS. SOURCE 1 (NORMAL) SOURCE 2 (EMERGENCY) LOAD ISOLATING CONTACTS AUTOMATIC TRANSFER SWITCH ES1968 BYPASS TRANSFER SWITCH FIGURE 1-1.
BTPC TRANSFER SWITCH (TYPICAL FUNCTION) Automatic transfer switches, capable of automatic operation without operator intervention, perform the basic function of transferring the load to the available source. The controller monitors each source for allowable voltage and frequency range.
PowerCommand is a registered trademark of Onan Corporation. Onan and Cummins are registered trademarks of Cummins Inc. 1-2 Bypass Switch Function The bypass switch allows the operator to manually connect the load to the available power source, by- passing the automatic transfer switch (Figure 1-1).
When bypassed, the automatic transfer switch can be isolated for service or removal without causing a power interruption. Drawout Isolation Mechanism The drawout isolation mechanism allows the auto- matic transfer switch to be withdrawn for testing or service. The transfer switch is mounted on rails and is connected to the load, power sources, and controls through isolation contacts. Turning a drawout cranking handle moves the automatic transfer switch along the rails and engages and disengages the isolation contacts to permit testing or service. If necessary, the switch can be lifted from its rails and removed for service. UTILITY-TO-GENSET OPERATION In utility-to-genset applications, the transfer switch performs the following functions: 1. Senses the interruption of the Source 1 pow- er.
Sends a start signal to the generator set (Source 2). Waits for the voltage to stabilize and then transfers the load to the Source 2.
Senses the return of Source1. Retransfers the load to Source 1. Sends a stop signal to the generator set. UTILITY-TO-UTILITY OPERATION In utility-to-utility applications, the transfer switch performs the following functions: 1.
Senses the interruption of the Source 1 pow- er. Transfers the load to the Source 2. Senses the return of Source 1. Retransfers the load to Source 1.
The controller can control a two-utility configura- tion for prime power. One utility is designated the preferred source. The control automatically trans- fers the load between the two utilities and detects alarm conditions. The exercise routine is not avail- able in this configuration.
The operator can select either source as the pre- ferred source (see Figure 1-2). The Preferred Source menu is included in the Test submenus (see Figure 4-17). The PC service tool can also be used to designate either source as the preferred source. Y Preferred Source Source 1/Source 2 ' FIGURE 1-2. PREFERRED SOURCE SUBMENU REMOVING AND REPLACING ELECTRONIC CONTROL COMPONENTS WARNING 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 J10/P10 before working on the electronic control sys- tem. Disconnecting J10/P10 removes all power to the door.
Be sure to remove all power before replacing elec- tronic control modules and components. This in- cludes removing one of the lithium batteries from the Digital Module. Reinstall the lithium battery af- ter performing service parts replacement. No special tools are required to remove and re- place control system components. Be sure to use all of the hardware when remounting components. Refer to “Power Module Test” on page 6-2 for spe- cial instructions when replacing the power mod- ules. If possible, use the InPowert service tool to create a capture file of the calibration and adjust- ment settings in the Digital Module.
Use the cap- ture file to write these settings to a replacement Digital Module. InPower is a trademark of Onan Corporation. 1-3 MODEL IDENTIFICATION Identify your model by referring to the Model and Specification number as shown on the nameplate. Electrical characteristics and application informa- tion are shown on the lower portion of the name- plate. The nameplate is located on the cabinet door. If it’s necessary to contact a dealer or distributor re- garding the transfer switch, always give the 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.
Feature/option codes are listed on the follow- ing page. The model number is made up of code segments that designate various features or options: BTPCB00000 Spec. A 1 2 3 4 1. BTPC − Bypass Transition PowerCommand Control.
Ampere Rating: B = 150−260 C = 300−400 (Spec A) C = 300−600 (Spec B) D = 600−1000 (Spec A) 3. Assigned Spec Number − issued for each specific combination of accessories, volt- ages, frequency and standards codes. Specification Letter − advances with produc- tion modification. HOW TO OBTAIN SERVICE When the transfer switch requires servicing, con- tact your nearest Cummins Power Generation dis- tributor. Factory-trained Parts and Service repre- sentatives are ready to handle all your service needs. To contact your local Cummins Power Generation (CPG) distributor in the United States or Canada, call 1-800-888-6626 (this automated service uti- lizes touch-tone phones only).
By selecting Option 1 (press 1), you will be automatically connected to the distributor nearest you. If you are unable to locate a dealer or distributor, consult the Yellow Pages. Typically, distributors are listed under: Generators-Electric, Engines-Gasoline or Engines-Diesel, or Recreational Vehicles-Equipment, Parts and Service.
For outside North America, call Cummins Power Generation, 1-763-574-5000, 7:30 AM to 4:00 PM, Central Standard Time, Monday through Friday. Or, send a fax to Cummins Power Generation us- ing the fax number 1-763-528-7290. When contacting your distributor, always supply the complete Model Number and Serial Number as shown on the nameplate.
There are a number of different factors to consider when selecting an automatic transfer switch for a diesel generator, the most important being size. Part one of this article will discuss the type of load, voltage rating and continuous current rating. Careful selection of an automatic transfer switch is important to ensure maximum reliability and adequate capability under both normal and emergency situations.
However, in the end, the most common influencing factors are price and reliability. Different Types of Loads Underwriters Laboratory is the prevailing authority figure when it comes to independent testing of electrical products. Underwriters Laboratory or UL classifies automatic transfer switch loads under guideline UL 1008. The loads listed are Total System Loads, Motor Load, Electric Discharge Lamp Loads, Restrictive Loads, and Incandescent Lamp Loads.
Underwriters Laboratory requires that all transfer switches for diesel generators be clearly marked to specify what type of load it is capable of handling. The “Total System Loads” panel indicates that the switch can be used for a variety of loads described in the previous paragraph. However, when dealing with an incandescent (tungsten based filament) load the total load should never exceed 30% unless the transfer switch is specifically rated to transfer a higher percentage of power to incandescent lamps. In general, most transfer switches for used generators are rated to handle Total System Loads.
It is always best to check the markings as some Total System Loads are marked “Resistance Only, Tungsten Only etc” The overall project management hassle is greatly reduced for engineers by choosing a Total System Load from the onset of the project. Voltage Ratings Automatic transfer switches for are unique in regards to their electrical distribution system in that they are one of only a few electrical devices that are designed to have two unsynchronized power sources connected to it. For example, this could mean that voltages impressed on one side of the insulation, in the unit, may actually be as high as 960 volts on a 480 volt AC system.
A well designed UL transfer switch will provide adequate spacing and insulation to cope with the increased voltage stress. It is due to this reason of increased stress on the unit that spacing in transfer switches should be less than those shown in Table 22.1 in UL 1008, regardless of the component used as part of the transfer switch. The voltage ratings for AC systems are typically 120, 208, 240, 480, 600 volts, single or polyphase.
Onan Ats Manuals
Standard frequencies are 50 or 60 hertz. Automatic transfer switches can be used for other voltages and frequencies if required, this also includes DC. Continuous Current Rating The standard expectation of an automatic transfer switch in regards to a continuous load is that the switch should be able to hold maximum value for three hours or more. Transfer switches differ widely from other emergency equipment in that they must continuously carry the current to critical loads, either from the normal source of power or emergency source.
Whereas, a standby engine generator set usually supplies power only during emergency periods. Automatic transfer switches for diesel generators are manufactured to meet continuous current ratings of 30-4000 amperes.
Typically, the most commonly used include 30, 40, 70, 80, 100, 150, 225, 260, 400, 600, 800, 1000, 1200, 1600, 2000, 3000 and 4000 amperes. Modern transfer switch technology is capable of carrying 100% of the rated current at an ambient temperature of 40° C. Transfer switches incorporating integral overcurrent protective devices may be limited-to a continuous load current no more than 80% of the switch rating.
Onan 1000 Amp Ats Manual
In modern switches there are control measures in place to make sure no more than 80% of the load is continuous. However in older units system failure is a possibility for exceeding 80%. Project engineers should anticipate future load requirements during the planning process. Not all projects require forethought into future load requirements however it is generally advisable to select a transfer switch with a continuous current rating equal to the total of the anticipated load. To calculate the continuous rating for a transfer switch one must total the amperes required for all loads. To determine the load current for tungsten (incandescent) lamps and electric heaters one must total the wattage value.
Mercury vapor, fluorescent vapor and sodium vapor lamp load currents must be based on the current that each ballast or autotransformer draws, not on the total watts of the lamps. Motor full load currents only determine motor loads and are not an accurate measure for other types of loads. Locked rotor and motor inrush currents do not need to be considered in sizing a transfer switch that is UL listed for the Total System Load. In most cases, there is no need to de-rate a transfer switch for use in ambient temperatures up to 40° C; this includes switches that are installed in the switchboard or in a separate enclosure.